Heat exchanger

ABSTRACT

A heat exchanger having light weight and an excellent recycling property and capable of exhibiting high sealing property of an air flow passage without using an adhesive agent. This heat exchanger is configured by alternately laminating heat transfer plates A and heat transfer plates B which are respectively integrated by vacuum molding a polystyrene sheet into heat transfer surface, air flow passage rib, air flow passage end surface, groove A, protrusion, outer peripheral rib A, outer peripheral rib B, air flow passage end surface cover, and a groove B. The groove A is brought into close contact with the groove B, upper surfaces of the outer peripheral rib A and the outer peripheral rib B are brought into close contact with the heat transfer plate, the protrusion is brought into close contact with the outer peripheral rib B and the groove B, the air flow passage end surface is brought into contact with the outer peripheral rib B, the air flow passage end surface cover is brought into contact with the end surfaces of the outer peripheral rib A and the outer peripheral rib B, and the side surfaces of the outer peripheral rib A are brought into contact with each other.

This Application is a U.S. National Phase Application of PCTInternational Application PCT/JP2003/007116.

TECHNICAL FIELD

The present invention relates to a heat exchanger for use in heatexchanging ventilation equipment or other air conditioning equipment, inwhich multiple heat transfer plates are laminated alternately and airflow passages A and air flow passages B are formed alternately.

BACKGROUND ART

Conventionally, as a conventional counter flow method heat exchanger ofthis type, the present applicant proposed a heat exchanger described in,for example, Japanese Patent Unexamined Application No. 8-75385.

Hereinafter, the heat exchanger is described with reference to FIGS. 44,45 and 46.

As shown in FIG. 44, for forming parallel air flow passages on one sideof flat plate 101 made of paper and the like, end ribs 102 a that aredisposed obliquely at substantially the same angles are provided in thevicinity of inlets and outlets of the air flow passages, and center ribs102 b connected to end ribs 102 a are provided in the center portion forforming counter flow portions. End rib 102 a and center rib 102 b formsubstantially S-shaped rib 102.

Furthermore, also on the rear surface of plate 101, similar to S-shapedribs 102 provided on the front surface, substantially S-shaped ribs 103each composed of end rib 103 a and center rib 103 b are provided in away in which end ribs 103 a on the rear surface are respectivelydisposed obliquely with respect to end ribs 102 a on the front surface,and center ribs 102 b provided on the front surface are disposedintersecting center ribs 102 b provided on the rear surface. Unit member104 is configured by integrating S-shaped ribs 102 and 103 by usingresin.

Between unit members 104, cut plate 105 made of paper and the like thatwas cut in a predetermined dimension is inserted. Unit member 104 andcut plate 105 are laminated so that the air flow passages A and the airflow passages B are formed alternately to form a heat exchanger. Fluidflowing in the air flow passage A and fluid flowing in the air flowpassage B exchange beat by way of plate 101 and cut plate 105.

As an attachment structure of handle 106 used for attaching anddetaching this type of heat exchanger to equipment and carrying the heatexchanger, for example, as shown in FIG. 47, a handle provided as aseparate member on at least one end surface of the both end surfaces inthe laminating direction has been known.

In such a conventional heat exchanger, since ribs other than plate 101of unit member 104 are solid, weight is heavy and material cost is high.

Since plate 101 made of paper and the like and ribs are integrated witheach other by using resin, it is difficult to classify a plurality ofmaterials for recycling, and thus a recycling property is low.

Furthermore, a sealing property of the air flow passages A and the airflow passages B is deteriorated because of accuracy defect in cuttingdimension and dislocation, and the like, of plates 101 and cut plates105.

When unit members 104 and cut plates 105 are laminated alternately, itis difficult to laminate unit members 104 and cut plates 105 whilepositioning thereof in order to prevent dislocation of cut plates 105,and thus productive efficiency is low.

Furthermore, since handle 106 is provided on the end surface in thelaminating direction of heat transfer plates, it is necessary to designequipment on which a heat exchanger is mounted in a way in which thedirection of attaching and detaching the heat exchanger become thelaminating direction, thus lowering the degree of freedom in designingof equipment on which the heat exchanger is mounted.

Furthermore, since fluid flowing in the air flow passages A and fluidflowing in the air flow passages B are opposed to each other in thecentral portion, although heat exchanging efficiency is improved ascompared with a heat exchanger composed of only air flow passages havingequal heat transferring areas that are disposed orthogonally orobliquely, the heat exchanging efficiency is still insufficient.

DISCLOSURE OF THE INVENTION

A heat exchanger comprises:

a heat transfer plate A and a heat transfer plate B;

a plurality of air flow passage ribs formed in a substantially S-shapedhollow convex and disposed substantially parallel to each other andsubstantially at equal intervals, the plurality of air flow passage ribsforming a plurality of substantially S-shaped air flow passages and heattransfer surfaces;

an air flow passage end surface provided at an inlet and an outlet ofthe air flow passage of the heat transfer plate A, the air flow passageend surface being provided obliquely or perpendicular to a direction ofthe inlet and outlet of the air flow passage and provided by folding theheat transfer surface in a direction opposite to a convex direction ofthe air flow passage rib;

a groove A provided parallel to the air flow passage end surface on theheat transfer plate A;

a plurality of protrusions each having a hollow shape being convex inthe same direction as the convex direction of the air flow passage rib,which are provided between the groove A and the air flow passage endsurface on extended lines of the plurality of air flow passage ribs onthe heat transfer surface in the vicinity of the air flow passage endsurface, each of the plurality of protrusions having a pair of sidesurfaces substantially parallel to the air flow passage end surface andbeing higher than a height in the convex direction of the plurality ofair flow passage ribs;

outer peripheral edge portions being other than portions of the inletsand outlets of the air flow passages on the heat transfer plate, theouter peripheral edge portions including one pair of outer peripheraledge portions A facing each other and being adjacent to the inlets andoutlets of the air flow passages and which are provided substantiallyparallel to substantially central portions of the plurality ofsubstantially S-shaped air flow passage ribs, and another pair of outerperipheral edge portions B facing each other and being adjacent to theinlets and outlets of the air flow passages and which are providedsubstantially parallel to the air flow passage rib in the portion of theinlets and outlets of the plurality of substantially S-shaped air flowpassages;

the outer peripheral edge portion A having an outer peripheral rib Aobtained by forming the heat transfer surface into a hollow shape thatis convex in the same direction as the convex direction of the air flowpassage rib, in which a convex height of the outer peripheral rib A ishigher than a height in a convex direction of the air flow passage rib Aand an outer side surface of the outer peripheral rib A is folded in adirection opposite to the convex direction of the air flow passage ribso as to have a folding dimension that is larger than a dimension of theheight in the convex direction of the outer peripheral rib A withrespect to the heat transfer surface;

the outer peripheral edge portion B having an outer peripheral rib Bobtained by forming the heat transfer surface into a hollow shape thatis convex in the same direction as the convex direction of the air flowpassage rib, in which a convex height of the outer peripheral rib B isthe same height in a convex direction of the air flow passage rib B anda central portion of an outer side surface of the outer peripheral rib Bis folded to the same plane as the heat transfer surface so as to havean opening portion at the outer side surface of the outer peripheral ribB;

an air flow passage end surface cover provided at both ends of the outerside surface of the outer peripheral rib B, which is folded to the sameposition as the folding position of the air flow passage end surface;and

a groove B provided on an upper surface of the outer peripheral rib B,the groove B being caved to the same plane as the heat transfer surface,on a position in which a distance between a side surface of the outerperipheral rib B and a center line of the groove B is equal to adistance between a center line of the groove A and the air flow passageend surface, in a shape in which an outer surface in a longitudinaldirection of the groove A is brought into close contact with an innersurface in a longitudinal direction of the groove B,

wherein the heat transfer plate B is mirror-image relation to the heattransfer plate A;

in a shape of the heat transfer plate B, a height in a convex directionof the outer peripheral rib A of the heat transfer plate B is allowed tobe the same as a height in a convex direction of the air flow passagerib;

furthermore, a width of the outer peripheral rib A of the heat transferplate B is larger than a width of the outer peripheral rib A provided inthe heat transfer plate A;

each of the heat transfer plate A and the heat transfer plate B isintegrated by using one sheet as a material, respectively;

the heat transfer plates A and the heat transfer plates B are laminatedalternately in a way in which the outer peripheral rib A of the heattransfer plate A and the outer peripheral rib A of the heat transferplate B are overlapped with each other; and

the heat transfer plates A and the heat transfer plates B are laminatedto each other, resulting in forming the air flow passage A and the airflow passage B alternately; and

wherein, when the heat transfer plates A and the heat transfer plates Bare laminated alternately,

-   -   upper surfaces of the air flow passage ribs, the protrusions,        the outer peripheral ribs A and the outer peripheral ribs B are        brought into contact with a heat transfer plate to be laminated        on an upper part thereof;

the groove B is brought into contact with an upper surface of the outerperipheral rib B provided on a heat transfer plate located in a lowerpart of the groove B;

a pair of side surfaces of the protrusions being parallel to the airflow passage end surface are brought into contact with at least one ofan inner side surface of the outer peripheral rib B and a side surfaceof the groove B provided in the heat transfer plate to be laminated onan upper part of the protrusions;

the air flow passage end surface is brought into contact with an outerside surface of the outer peripheral rib B provided on a heat transferplate located in a lower part of the air flow passage end surface;

side surfaces of the outer peripheral ribs A provided respectively onthe heat transfer plate A and the heat transfer plate B are brought intocontact with each other; and

the air flow passage end surface cover is brought into contact with anend surface of the outer peripheral rib A and the outer peripheral rib Bprovided on a heat transfer plate located in a lower part of the airflow passage end surface cover.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic exploded perspective view showing a heat exchangerin accordance with Example 1 of the present invention.

FIG. 2 is a schematic perspective view showing a laminated state inaccordance with Example 1.

FIG. 3 is a schematic sectional view showing a laminated state of a sidesurface portion in accordance with the Example 1.

FIG. 4 is a schematic sectional view showing a laminated state of theportion of inlets and outlets of air flow passages in accordance withExample 1.

FIG. 5 is a schematic perspective projection plan view showing alaminated state of a corner portion in which the portion of inlets andoutlets of air flow passages are adjoined to each other in accordancewith the Example 1.

FIG. 6 is a schematic perspective projection front view showing alaminated state of a corner portion in which the portion of inlets andoutlets of air flow passages are adjoined to each other in accordancewith the Example 1.

FIG. 7 is a schematic front view showing a laminated state of a cornerportion in which the portion of inlets and outlets of air flow passagesare adjoined to each other in accordance with the Example 1.

FIG. 8 is a schematic front view showing a laminated state of theportion of inlets and outlets of air flow passages at side of the sidesurface in accordance with the Example 1.

FIG. 9 is a schematic perspective view showing a vacuum molding die fora heat transfer plate of a heat exchanger in accordance with Example 2of the present invention.

FIG. 10 is a schematic enlarged perspective view showing a heat transferplate in accordance with Example 2.

FIG. 11 is a schematic sectional view showing an air flow passageopening portion of the heat transfer plate in accordance with Example 2.

FIG. 12 is a schematic perspective view showing a method of cutting theheat transfer plate in accordance with Example 2.

FIG. 13 is a schematic sectional view showing a cutting position of theair flow passage opening portion of the heat transfer plate inaccordance with Example 2.

FIG. 14 is a schematic perspective view showing a heat exchanger inaccordance with Example 3 of the present invention.

FIG. 15 is a schematic perspective view showing a thermal weldingapparatus in accordance with Example 3.

FIG. 16 is a schematic perspective view showing a heat exchanger inaccordance with Example 4 of the present invention.

FIG. 17 is a schematic perspective view showing the thermal weldingapparatus in accordance with Example 4.

FIG. 18 is a schematic perspective view showing a heat exchanger inaccordance with Example 5 of the present invention.

FIG. 19 is a schematic perspective view showing a thermal weldingapparatus in accordance with Example 5.

FIG. 20 is a schematic perspective view showing a first process of athermal welding apparatus in accordance with Example 6 of the presentinvention.

FIG. 21 is a schematic perspective view showing the first process of athermal welding apparatus in accordance with Example 6.

FIG. 22 is a schematic perspective view showing a thermal weldingapparatus in accordance with Example 7 of the present invention.

FIG. 23 is a schematic perspective view showing a heat exchanger inaccordance with Example 8 of the present invention.

FIG. 24 is a schematic exploded view showing the heat exchanger inaccordance with Example 8.

FIG. 25 is a schematic perspective view showing another embodiment of aheat exchanger in accordance with Example 8.

FIG. 26 is a schematic exploded view showing the heat exchanger inaccordance with Example 8.

FIG. 27 is a schematic perspective view showing a heat exchanger inaccordance with Example 9 of the present invention.

FIG. 28 is a schematic exploded view showing the heat exchanger inaccordance with Example 9.

FIG. 29 is a schematic perspective view showing a heat exchanger inaccordance with Example 10 of the present invention.

FIG. 30 is a schematic exploded view showing the heat exchanger inaccordance with Example 10.

FIG. 31 is a schematic perspective view showing another embodiment of aheat exchanger in accordance with Example 10.

FIG. 32 is a schematic exploded view showing the heat exchanger inaccordance with Example 10.

FIG. 33 is a schematic perspective view showing a heat exchanger inaccordance with Example 11 of the present invention.

FIG. 34 is a schematic exploded view showing the heat exchanger inaccordance with Example 11.

FIG. 35 is a schematic perspective view showing a heat exchanger inaccordance with Example 12 of the present invention.

FIG. 36 is a schematic perspective view showing a laminated state inaccordance with Example 12.

FIG. 37 is a schematic sectional view showing a laminated state of aside surface portion in accordance with Example 12.

FIG. 38 is a schematic exploded perspective view showing the heatexchanger in accordance with Example 12.

FIG. 39 is a schematic perspective view showing a laminated state inaccordance with Example 12.

FIG. 40 is a schematic exploded perspective view showing a heatexchanger in accordance with Example 13 of the present invention.

FIG. 41 is a schematic perspective view showing a laminated state inaccordance with Example 13.

FIG. 42 is a schematic exploded perspective view showing a heatexchanger in accordance with Example 14 of the present invention.

FIG. 43 is a schematic perspective view showing a laminated state inaccordance with Example 14.

FIG. 44 is a schematic perspective view showing a unit member of a heatexchanger in accordance with a conventional Example.

FIG. 45 is a schematic perspective view showing a laminated state inaccordance with a conventional Example.

FIG. 46 is a schematic exploded view at the time of laminating inaccordance with a conventional Example.

FIG. 47 is a schematic perspective view showing a state in which ahandle is provided in accordance with a conventional Example.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention was made to solve the above-mentioned conventionalproblems and the object of the present invention is to provide a heatexchanger capable of achieving light weight, low material cost,improvement of a recycling property, structure with a high sealingproperty, improvement in productive efficiency, a structure having adegree of freedom in the direction it is attached and detached, andimprovement in heat exchanging efficiency.

According to the present invention, a heat exchanger includes a heattransfer plate A and a heat transfer plate B. The heat transfer plate Aincludes a plurality of air flow passage ribs formed in a substantiallyS-shaped hollow convex and disposed substantially parallel to each otherand substantially at equal intervals, the plurality of air flow passageribs forming a plurality of substantially S-shaped air flow passages andheat transfer surfaces; and an air flow passage end surface provided atan inlet and an outlet of the air flow passage of the heat transferplate A, the air flow passage end surface being provided obliquely orperpendicular to a direction of the inlet and outlet of the air flowpassage and provided by folding the heat transfer surface in a directionopposite to a convex direction of the air flow passage rib; a groove Aprovided parallel to the air flow passage end surface on the heattransfer plate A; a plurality of protrusions each having a hollow shapebeing convex in the same direction as the convex direction of the airflow passage rib, which are provided between the groove A and the airflow passage end surface on extended lines of the plurality of air flowpassage ribs on the heat transfer surface in the vicinity of the airflow passage end surface, each of the plurality of protrusions having apair of side surfaces substantially parallel to the air flow passage endsurface and being higher than a height in the convex direction of theplurality of air flow passage ribs; outer peripheral edge portions beingother than portions of the inlets and outlets of the air flow passageson the heat transfer plate, the outer peripheral edge portions includingone pair of outer peripheral edge portions A facing each other and beingadjacent to the inlets and outlets of the air flow passages and whichare provided substantially parallel to substantially central portions ofthe plurality of substantially S-shaped air flow passage ribs, andanother pair of outer peripheral edge portions B facing each other andbeing adjacent to the inlets and outlets of the air flow passages andwhich are provided substantially parallel to the air flow passage rib inthe portion of the inlets and outlets of the plurality of substantiallyS-shaped air flow passages; the outer peripheral edge portion A havingan outer peripheral rib A obtained by forming the heat transfer surfaceinto a hollow shape that is convex in the same direction as the convexdirection of the air flow passage rib, in which a convex height of theouter peripheral rib A is higher than a height in a convex direction ofthe air flow passage rib A and an outer side surface of the outerperipheral rib A is folded in a direction opposite to the convexdirection of the air flow passage rib so as to have a folding dimensionthat is larger than a dimension of the height in the convex direction ofthe outer peripheral rib A with respect to the heat transfer surface;the outer peripheral edge portion B having an outer peripheral rib Bobtained by forming the heat transfer surface into a hollow shape thatis convex in the same direction as the convex direction of the air flowpassage rib, in which a convex height of the outer peripheral rib B isthe same height in a convex direction of the air flow passage rib B anda central portion of an outer side surface of the outer peripheral rib Bis folded to the same plane as the heat transfer surface so as to havean opening portion at the outer side surface of the outer peripheral ribB; an air flow passage end surface cover provided at both ends of theouter side surface of the outer peripheral rib B, which is folded to thesame position as the folding position of the air flow passage endsurface; and a groove B provided on an upper surface of the outerperipheral rib B, the groove B being caved to the same plane as the heattransfer surface, on a position in which a distance between a sidesurface of the outer peripheral rib B and a center line of the groove Bis equal to a distance between a center line of the groove A and the airflow passage end surface, in a shape in which an outer surface in alongitudinal direction of the groove A is brought into close contactwith an inner surface in a longitudinal direction of the groove B. Theheat transfer plate B is mirror-image relation to the heat transferplate A; in a shape of the heat transfer plate B, a height in a convexdirection of the outer peripheral rib A of the heat transfer plate B isallowed to be the same as a height in a convex direction of the air flowpassage rib; furthermore, a width of the outer peripheral rib A of theheat transfer plate B is larger than a width of the outer peripheral ribA provided in the heat transfer plate A; each of the heat transfer plateA and the heat transfer plate B is integrated by using one sheet as amaterial, respectively; the heat transfer plates A and the heat transferplates B are laminated alternately in a way in which the outerperipheral rib A of the heat transfer plate A and the outer peripheralrib A of the heat transfer plate B are overlapped with each other; andthe heat transfer plates A and the heat transfer plates B are laminatedto each other, resulting in forming the air flow passage A and the airflow passage B alternately. When the heat transfer plates A and the heattransfer plates B are laminated alternately, upper surfaces of the airflow passage ribs, the protrusions, the outer peripheral ribs A and theouter peripheral ribs B are brought into contact with a heat transferplate to be laminated on an upper part thereof; the groove B is broughtinto contact with an upper surface of the outer peripheral rib Bprovided on a heat transfer plate located in a lower part of the grooveB; a pair of side surfaces of the protrusions being parallel to the airflow passage end surface are brought into contact with at least one ofan inner side surface of the outer peripheral rib B and a side surfaceof the groove B provided in the heat transfer plate to be laminated onan upper part of the protrusions; the air flow passage end surface isbrought into contact with an outer side surface of the outer peripheralrib B provided on a heat transfer plate located in a lower part of theair flow passage end surface; side surfaces of the outer peripheral ribsA provided respectively on the heat transfer plate A and the heattransfer plate B are brought into contact with each other; and the airflow passage end surface cover is brought into contact with an endsurface of the outer peripheral rib A and the outer peripheral rib Bprovided on a heat transfer plate located in a lower part of the airflow passage end surface cover. With this, the following effect isexhibited. When the heat transfer plates A and the heat transfer platesB are laminated alternately, the outer surface of the groove A isbrought into close contact with the inner surface of the groove B in theadjacent heat transfer plates; the upper surface of the outer peripheralrib A and the upper surface of the outer peripheral rib B are broughtinto close contact with the heat transfer plate laminated on the upperpart; the air flow passage end surface is brought into contact with theouter side surface of the outer peripheral rib B provided on a heattransfer plate located in the lower part; the side surfaces of the outerperipheral rib A provided on the adjacent heat transfer plates arebrought into contact with each other; and the air flow passage endsurface cover is brought into contact with the end surfaces of the outerperipheral rib A and the outer peripheral rib B provided on a heattransfer plate located in the lower part. Thus, the air flow passage Aand the air flow passage B are sealed with each other at the peripheralportions thereof. The protrusions provided at the inlet and outlet ofthe air flow passage A and the air flow passage B are brought into closecontact with the rear surface of the outer peripheral rib B formed onthe heat transfer plate laminated on the upper part. Thereby, thesealing property between the outer peripheral rib B formed on a heattransfer plate to be laminated on the upper part of the protrusions anda heat transfer surface formed on a heat transfer plate to be laminatedon the further upper part is improved. The groove A provided in theinlet and outlet of air flow passage reinforces a heat transfer plate onthe inlet and outlet portion of the air flow passage; and the groove Bprovided on the upper surface of the outer peripheral rib B reinforcesthe outer peripheral rib B. Thereby, the upper surface of the outerperipheral rib B and the heat transfer plate laminated on the upper partare suppressed from being deformed when they are brought into closecontact with each other, and the sealing property is improved. In aposition where the outer peripheral ribs B provided in the adjacent heattransfer plates intersect each other, the groove B provided on the heattransfer plate laminated on the upper part is brought into contact withthe upper surface of the outer peripheral rib B provided on a heattransfer plate located in the lower part. Thereby, deformation in thelaminating direction is suppressed and deterioration in the sealingproperty due to the deformation can be prevented. The outer surface ofthe groove A is brought into close contact with the inner surface of thegroove B of the adjacent heat transfer plates. The air flow passage endsurface is brought into contact with the outer side surface of the outerperipheral rib B provided on a heat transfer plate located in the lowerpart; the side surfaces of the outer peripheral ribs A provided in theadjacent heat transfer plates are brought into contact with each other;the air flow passage end surface cover is brought into contact with theend surfaces of the outer peripheral rib A and the outer peripheral ribB provided on a heat transfer plate located in the lower part; and apair of side surfaces that are parallel to the air flow passage endsurface provided on the protrusion are brought into contact with atleast one of the inner side surface of the outer peripheral rib B andthe side surface of the groove B, which are provided on the heattransfer plate laminated on the upper part. Thus, dislocation of thelaminated heat transfer plates is suppressed and the sealing propertiesof the air flow passage A and the air flow passage B are prevented frombeing deteriorated due to the dislocation. Thus, positioning can becarried out easily when the heat transfer plates are laminated, and theair flow passage ribs, the outer peripheral ribs A, the outer peripheralribs B and the protrusions are molded in a hollow shape by using onesheet. Consequently, light weight and the reduction in the amount ofmaterials can be realized. Since the heat transfer plate is molded by asheet of a single material, a recycling property can be improved. Fluidis also flown to the inner surface of the air flow passage rib and heatexchange can be carried out also in the air flow passage rib, and thus,heat exchanging efficiency is improved.

Furthermore, a thermoplastic resin sheet is used as a sheet material.With the feature of the thermo plastic resin that molding can be carriedout easily for a short time, an effect of improving productiveefficiency is exhibited.

Furthermore, a styrene resin sheet is used as a sheet material. With thefeature that the styrene resin sheet is hard, the effect is exhibited,in which the strength at the time of laminating in portions in whichadjacent heat transfer plates are brought into close contact with eachother or brought into contact with each other can be secured, and thus asealing property is improved and at the same time, workability isexcellent and productive efficiency is improved.

Furthermore, a polystyrene resin sheet is used as a sheet material. Withthis material, the effect is exhibited, in which material cost is low,shrinkage is small, dimension stability is excellent, dimension accuracyof a molded product is high, a sealing property is improved, moldabilityis excellent and productive efficiency is improved.

Furthermore, when the heat transfer plates A and the heat transferplates B are integrated with each other, by carrying out a moldingprocess by the use of a molding die having a rectangular shaped portionthat continues to the outer side surface of the outer peripheral rib Band has a cross sectional shape equal to an opening portion formed onthe outer side surface of the outer peripheral rib B, and then cutting aportion formed by the rectangular shaped portion and a sheet portionother than the heat transfer plate A and the heat transfer plate B alongthe outer side surfaces of the heat transfer plate A and the heattransfer plate B, the heat transfer plate A and the heat transfer plateB are manufactured. With this, the following effect is exhibited. Sincethe outer periphery of the heat transfer plate is cut in a predetermineddimension and at the same time, an opening portion of the inlet andoutlet of the air flow passage provided on the side surface of the outerperipheral rib B is formed, productivity is enhanced as compared with aworking process for forming an opening portion of the inlet and outletby molding the side surface portion of the outer peripheral rib B to thefolding positions of the air flow passage end surface covers provided atboth ends of the side surface of the outer peripheral rib B, and thencutting the central portion of the side surface portion of the outerperipheral rib B.

Furthermore, in at least two corner portions of the heat transfer plateA and the heat transfer plate B, overlapped portions of the air flowpassage end surface cover, the outer peripheral rib A, the outerperipheral rib B or the air flow passage end surface, which are formedon an outer side surface of adjacent heat transfer plates, are thermallywelded over an entire length in the laminated direction. With this, thefollowing effect is exhibited. In the laminated adjacent heat transferplates, the air flow passage end surface cover and the end surface ofouter peripheral rib A, the air flow passage end surface cover and theend surface of outer peripheral rib B, the air flow passage end surfaceand the side surface of outer peripheral rib B, and the side surfaces ofouter peripheral rib A are thermally welded to be fixed, respectively.Thus, deterioration of the sealing property of the air flow passages dueto dislocation of the heat transfer plates is prevented and the sealingproperty is improved.

Furthermore, in a surface on which the inlets and outlets of the airflow passages A and the air flow passages B are formed, overlappedportions of the air flow passage end surface cover, the outer peripheralrib A, the outer peripheral rib B and the air flow passage end surface,which are formed on an outer side surface of adjacent heat transferplates, are thermally welded over an entire surface. With this, thefollowing effect is exhibited. In the laminated adjacent heat transferplates, the air flow passage end surface and the side surface of theouter peripheral rib A, the air flow passage end surface cover and theside surface of the outer peripheral rib A, and the air flow passage endsurface cover and the side surface of the outer peripheral rib B arethermally welded, respectively. Thus, the outer side surface of outerperipheral ribs B of another air flow passage facing the inlet andoutlet portion of one air flow passage is sealed. Furthermore,dislocation of the heat transfer plates is suppressed and the sealingproperty of the air flow passages is improved.

Furthermore, overlapped portions on an outer side surface of adjacentheat transfer plates are thermally welded over an entire surface. Withthis, the following effect is exhibited. In the laminated adjacent heattransfer plates, the air flow passage end surface and the side surfaceof the outer peripheral rib A, the air flow passage end surface coverand the side surface of the outer peripheral rib A, and the air flowpassage end surface cover and the end surface of the outer peripheralrib B are thermally welded, respectively. Thus, the outer side surfaceof outer peripheral ribs B of another air flow passage facing the inletand outlet portion of one air flow passage is sealed. Furthermore, outerside surfaces of the outer peripheral ribs A of the laminated adjacentheat transfer plates are thermally welded. Thereby, dislocation of theheat transfer plates is suppressed and that the sealing property of theair flow passages is improved.

Furthermore, when adjacent portions on an outer side surface of the heatexchanger is thermally welded, the adjacent portions on an outer sidesurface of the heat exchanger is thermally welded simultaneously by athermal welding means having a thermally welding surface having a shapecorresponding to a shape of the adjacent portions on an outer sidesurface of the heat exchanger. With this, the following effect isexhibited. Since adjacent portions to be thermally welded that are notpresent on the same plane are thermally welded simultaneously,productive efficiency is improved.

Furthermore, when adjacent portions on an outer side surface of the heatexchanger are thermally welded, by vertically pressing a thermal weldingmeans having substantially the same shape as respective surfaces to bethermally welded to a surface to be thermally welded, the outer sidesurface of the heat exchanger is thermally welded. With this, thefollowing effect is exhibited. By vertically pressing the thermalwelding means to a surface to be thermally welded, the adhesiveness atthe time of thermal welding in the portion in which the outer sidesurfaces of the heat transfer plates are overlapped with each other isimproved and the sealing property is improved.

Furthermore, the outer side surface of the heat exchanger is thermallywelded by the use of a thermal welding means having a cylindrical-shapedthermally welding surface, by pressing the thermally welding surface ofthe thermal welding means to the heat exchanger and moving whilerotating it from an upper part to a lower part along a laminatingdirection of the heat transfer plates. With this, the following effectis exhibited. Since the thermal welding means moves while rotating fromthe upper part to the lower part along the laminating direction, thedirection in which the thermal welding means is rotated and thedirection in which the outer peripheral side surface of the heattransfer plate is folded are the same. Consequently, the occurrence ofwarp, folding, or the like, of the outer peripheral side surface of theheat transfer plate at the time of thermal welding is prevented.Furthermore, the direction of level difference between the cut portionof the outer side surface of the heat transfer plate and the outerperipheral side surface of the heat transfer plate located in the lowerpart, which occurs due to overlapping of the outer side surfaces of theheat transfer plates, is substantially parallel to the thermal weldingmeans. Consequently, defective thermal welding due to the leveldifference in the outer side surfaces of the heat transfer plates isprevented, and thus a heat exchanger with a high sealing property can beobtained.

Furthermore, the heat exchanger includes the first end surface members,which are facing each other, at both end surfaces in the laminatingdirection in which the heat transfer plates A and the heat transferplates B are laminated alternately; a side surface plate covering anouter side surface of the laminated heat transfer plates A and the heattransfer plates B and which is provided at an outer peripheral edgeportion of the first end surface member; a support member provided on anouter side surface of the outer peripheral rib A of the laminated heattransfer plates with both ends thereof coupled to the first end surfacemembers; elastic bodies included between the first end surface membersand the heat transfer plates located at both ends, respectively, theelastic body having a shape of pressing at least outer peripheral edgeportions of the heat transfer plates located at both end surfaces; and ahandle provided on at least one of the first end surface member and thesupport member. With this, the following effect is exhibited. Since ahandle is provided in the direction perpendicular to the laminatingdirection of the heat transfer plates or in the laminating direction, aheat exchanger can be attached and detached to/from equipment in thelaminating direction or in the direction perpendicular to the laminatingdirection, so that the direction of attaching and detaching the heatexchanger to/from equipment is expanded. Since the side surface plate isformed in a shape covering the outer side surface of the heat transferplates, fluid is suppressed from flowing into the portion between thefirst end surface member and the heat transfer plates located at bothends. Since the elastic body presses at least the outer peripheralportion of heat transfer plate located at both end surfaces, sealing iscarried out between the first end surface members and the heat transferplates located at both ends, respectively. Furthermore, since the sidesurface plate is formed in a shape covering the outer side surface ofthe heat transfer plates, positioning can be carried out easily.

Furthermore, the first end surface members and the support members areintegrated with each other with one of the support members separated.After the integrated first end surface members and support members areattached to the laminated heat transfer plates, the separated portion ofthe separated support member is coupled. The first end surface member isdisposed at the end surface of the laminated heat transfer plates viathe elastic body. After the support member is disposed on the outer sidesurface of the outer peripheral ribs A of the laminated heat transferplates, a coupling operation between the first end surface member andthe support member is carried out only by the coupling operation of theseparated portion of the separated support member.

Furthermore, the heat exchanger includes second end surface membersaffixed to heat transfer plates located at both end surfaces of thealternately laminated heat transfer plates A and heat transfer plates B,the second end surface member being formed of an elastic body molded ina shape that is the same as a shape of the outer peripheral edge portionof at least the heat transfer plate A or the heat transfer plate B; anda band-like handle member provided along at least one side surface ofthe outer side surface of the outer peripheral rib A, the band-likehandle member being fixed to the heat transfer plates located at bothend surfaces by the second end surface members. With this, the followingeffect is exhibited. An operation of affixing the second end surfacemembers to the heat transfer plates located at both end surfaces of thelaminated heat transfer plates respectively and an operation of fixingthe band-like handle member are carried out simultaneously. Furthermore,since the second end surface member is formed of an elastic body, thesecond end surface member is pressed in the laminating direction whenthe heat exchanger is mounted onto equipment and the sealing is carriedout at the end surfaces of the heat exchanger when the heat exchanger ismounted onto equipment. Since the band-like handle member is providedalong at least one surface of the outer side surfaces of the outerperipheral rib A of the laminated heat transfer plates, the heatexchanger can be attached and detached in the direction of the sidesurfaces of the outer peripheral rib A.

Furthermore, the heat exchanger includes second end surface membersaffixed to heat transfer plates located at both end surfaces of thealternately laminated heat transfer plates A and heat transfer plates B,the second end surface member being formed of an elastic body molded ina shape that is the same as a shape of the outer peripheral edge portionof at least the heat transfer plate A or the heat transfer plate B; anda band-like handle member provided along the outer side surface of theouter peripheral rib A, the band-like handle member being fixed to theheat transfer plate located at the end surface by the second end surfacemember at one end surface in the laminating direction of the laminatedheat transfer plates, and disposed at the outside of the second endsurface member at another end in the laminating direction of thelaminated heat transfer plates. With this, the following effect isexhibited. An operation of affixing the second end surface member to theheat transfer plate located at one of the end surfaces of the laminatedheat transfer plates and an operation of fixing the band-like handlemember are carried out simultaneously. Furthermore, since the second endsurface member is formed of an elastic body, the second end surfacemember is pressed in the laminating direction when the heat exchanger ismounted onto equipment and the sealing is carried out at the endsurfaces of the heat exchanger when the heat exchanger is mounted ontoequipment. Since the band-like handle member is provided along at leastone surface of the outer side surfaces of the outer peripheral rib A ofthe laminated heat transfer plates, the heat exchanger can be attachedand detached in the laminating direction of the heat transfer plates orin the laminating direction of the heat transfer plates and thedirection of side surface of the outer peripheral rib A.

Furthermore, a side surface reinforcement convex portion is provided onan upper surface of the outer peripheral rib A of the heat transferplate B, and when the heat transfer plates A and the heat transferplates B are laminated alternately, an upper surface of the outerperipheral rib A formed on the heat transfer plate A is brought intocontact with a rear surface of the outer peripheral rib A formed on theheat transfer plate B, an upper surface of the outer peripheral rib Aformed on the heat transfer plate B is brought into contact with a rearsurface of the heat transfer surface provided on the heat transfer plateA, and an upper surface and a side surface of the side surfacereinforcement convex upper surface formed on the outer peripheral rib Aof the heat transfer plate B are brought into contact with a rearsurface and a side surface of the outer peripheral rib A formed on theheat transfer plate A. With this, the following effect is exhibited.When adjacent surfaces of the outer side surfaces of the outerperipheral ribs A of the heat exchanger are thermally welded, since theside surface reinforcement convex portion of the heat transfer plate Bis brought into contact with a hollow convex portion of the outerperipheral ribs A of the heat transfer plate A, after heated transferplates are melted, when a temperature decreases and respective heattransfer plates are welded, deformation of the side surface portion dueto temperature shrinkage is prevented. Furthermore, deterioration ofsealing property due to deformation is prevented and the sealingproperty of the side surface portion is improved.

Furthermore, the side surface reinforcement convex portion is formed ina discontinuous structure. With this, the following effect is exhibited.When adjacent surfaces of the outer side surfaces of the outerperipheral ribs A of the heat exchanger are thermally welded, since theside surface reinforcement convex portion of the heat transfer plate Bis brought into contact with a hollow convex portion of the outerperipheral ribs A of the heat transfer plate A, after heated transferplates are melted, when a temperature decreases and respective heattransfer plates are welded, deformation of the side surface portion dueto temperature shrinkage is prevented. Furthermore, deterioration ofsealing property due to deformation is prevented and the sealingproperty of the side surface portion is improved.

Furthermore, a side surface reinforcement convex portion is provided onan upper surface of the outer peripheral rib A of the heat transferplate A and the heat transfer plate B, and when the heat transfer platesA and the heat transfer plates B are laminated alternately, an uppersurface and a side surface of the side surface reinforcement convexportion formed on the heat transfer plate A are brought into contactwith a rear surface and a side surface of the outer peripheral rib Aformed on the heat transfer plate B, and an upper surface and a sidesurface of the side surface reinforcement convex portion formed on theheat transfer plate B are brought into contact with a rear surface and aside surface of the outer peripheral rib A. With this, the followingeffect is exhibited. When adjacent surfaces of the outer side surfacesof the outer peripheral ribs A of the heat exchanger are thermallywelded, since the side surface reinforcement convex portion is broughtinto contact with a hollow convex portion of the outer peripheral ribs Aof the heat transfer plate A and the heat transfer plate B, after heatedtransfer plates are melted, when a temperature decreases and respectiveheat transfer plates are welded, deformation of the side surface portiondue to temperature shrinkage is prevented. Furthermore, deterioration ofsealing property due to deformation is prevented and the sealingproperty of the side surface portion is improved.

Furthermore, when the heat transfer plates A and the heat transferplates B are laminated alternately, an upper surface and a side surfaceof the outer peripheral rib A formed on the heat transfer plate A arebrought into contact with a rear surface and a side surface of the outerperipheral rib A formed on the heat transfer plate B, and an uppersurface and a side surface of the side surface reinforcement convexportion formed on the outer peripheral rib A of the heat transfer plateB are brought into contact with a rear surface and a side surface of theouter peripheral rib A formed on the heat transfer plate A. With this,the following effect is exhibited. When adjacent surfaces of the outerside surfaces of the outer peripheral ribs A of the heat exchanger arethermally welded, since the side surface reinforcement convex portion ofthe heat transfer plate B is brought into contact with a hollow convexportion of the outer peripheral ribs A of the heat transfer plate A,after heated transfer plates are melted, when a temperature decreasesand respective heat transfer plates are welded, deformation of the sidesurface portion due to temperature shrinkage is prevented. Furthermore,deterioration of sealing property due to deformation is prevented andthe sealing property of the side surface portion is improved.

Hereinafter, Examples of the present invention are described withreference to drawings.

EXAMPLE 1

Hereinafter, Example 1 of the present invention is described withreference to FIGS. 1, 2, 3, 4, 5, 6, 7 and 8.

FIG. 1 is a schematic exploded perspective view showing a heat exchangerused in this Example; FIG. 2 is a schematic perspective view showing astate in which heat transfer plates are laminated; FIG. 3 is a schematicsectional view showing a side surface portion thereof; FIG. 4 is aschematic sectional view showing a portion of inlets and outlets of airflow passages thereof; FIG. 5 is a schematic perspective projection planview showing a corner portion in which the portion of inlets and outletsof air flow passages A and the portion of inlets and outlets of air flowpassages B are adjoined to each other; FIG. 6 is a schematic perspectiveprojection front view thereof; FIG. 7 is a schematic front view thereof;and FIG. 8 is a schematic front view showing the portion of inlets andoutlets of air flow passages at the side of the side surface of the heattransfer plate.

In FIGS. 1 and 2, a heat exchanger configured by alternately laminatingheat transfer plates A1 and heat transfer plates B2 is a counter-flowtype heat exchanger in which air flow passages A3 and air flow passagesB4 are provided at the upper and lower parts of the respective heattransfer plates, fluid flowing in air flow passages A3 exchanges heatvia the respective heat transfer plates, flows obliquely each other inportions of inlets and outlets of the respective air flow passages, andflows in the direction in which they are opposing to each other in thecentral portions of the air flow passages.

Actually, multiple heat transfer plates A1 and heat transfer plates B2are laminated alternately. However, for simplification, only four heattransfer plates are shown.

Heat transfer plate A1 and heat transfer plate B2 are molded by vacuummolding process of a polystyrene sheet having a hexagonal planar shapeand thickness of, for example, 0.2 mm. Heat transfer plate A1 has eightsubstantially S-shaped air flow passage ribs 6 provided substantiallyparallel to each other and at equal intervals, and each air flow passagerib 6 is formed in a hollow convex shape and has a convex height of, forexample, 2 mm with respect to the surface of heat transfer surface 5.Air flow passage ribs 6 form substantially S-shaped air flow passages A3and heat transfer surfaces 5. In the portion of inlets and outlets ofair flow passages A3, air flow passage end surface 7 is provided byfolding the edge of heat transfer plate A1 to, for example, a positionthat is 2.2 mm with respect to the surface of heat transfer surface 5 inthe direction opposite to the convex direction of air flow passage rib6. Groove A8 is provided parallel to air flow passage end surface 7 onheat transfer surface 5 at the inner side from air flow passage endsurface 7 at, for example, a position with a distance from air flowpassage end surface 7 to the center line of groove A8 of 4.5 mm in a wayin which the outer dimension of the width of groove A8 is 2 mm. Onextended lines of air flow passage ribs 6 between groove A8 and air flowpassage end surface 7, a plurality of protrusions 9 each having a hollowconvex shape in the same direction as the convex direction of the airflow passage rib 6 and being higher than air flow passage rib 6 areformed in the vicinity of the air flow passage end surface. For example,eight protrusions having a height of 4 mm with respect to heat transfersurface 5 are provided. Protrusion 9 has a pair of side surfaces 10 aand 10 b parallel to air flow passage end surface 7 and top surface 11parallel to heat transfer surface 5. In a pair of outer peripheral edgeportions that are substantially parallel to air flow passage portionsflowing in the opposite directions in the outer peripheral edge portionsof heat transfer plate A1, outer peripheral ribs A12 formed to have ahollow convex shape in the same direction as the convex direction of airflow passage rib 6 and to have the same height as that of protrusion 9are provided in a way in which the width of outer peripheral rib A12 is,for example, 4 mm. The top surface of outer peripheral rib A12 isparallel to heat transfer surface 5 and the outer side surface is foldedto the same position as that of air flow passage end surface 7. In apair of outer peripheral edge portions that are substantially parallelto the air flow passage portions flowing obliquely in the outerperipheral edge portions of heat transfer plate A1, outer peripheralribs B13 formed to have a hollow convex shape in the same direction asthe convex direction of air flow passage rib 6 and to have the sameheight as air flow passage rib 6 are provided in a way in which thewidth of outer peripheral rib B13 is, for example, 7 mm. The top surfaceof outer peripheral rib B13 is parallel to heat transfer surface 5 andthe central portion of the outer side surface is folded to the sameposition as heat transfer surface 5 to form air flow passage openingportion 14. Both end portions, for example, the portions that are 8 mmdistant from the corner are folded to the same position as air flowpassage end surface 7 to form air flow passage end surface cover 15. Thetop surface of outer peripheral rib B13 is provided with groove B16.Groove B16 is caved to the same plane as heat transfer plate in a way inwhich the distance between the folded position of the outer side surfaceof the top surface of outer peripheral rib B13 and the central line ofgroove B is equal to the distance between the central line of groove A8and the folded position of air flow passage end surface 7 in a way inwhich the outer surface in the longitudinal direction of groove A8 is aclose contact with the inner surface in the longitudinal direction ofgroove B16 and the inner dimension of the width of groove B16 is, forexample, 2 mm.

With the configuration in which eight air flow passage ribs 6 areprovided substantially parallel to each other at substantially equalintervals and outer peripheral ribs A12 and outer peripheral ribs B13are disposed substantially parallel to air flow passage ribs 6, the flowof respective fluid flowing in plurality of air flow passages A3 formedof air flow passage ribs 6, outer peripheral ribs A12 and outerperipheral ribs B13 is uniformed. Thus, the increase in the air-flowresistance is suppressed, and entire region of heat transfer surfaces 5of heat transfer plate A1 efficiently functions in heat exchange.

Furthermore, heat transfer plate B2 is mirror-image relation to heattransfer plate A1. In the shape of heat transfer plate B2, the height ofouter peripheral rib A12 of heat transfer plate B2 is allowed to beequal to that of air flow passage rib 6 and the width of outerperipheral rib A12 of heat transfer plate B2 is allowed to be largerthan that of outer peripheral rib A12 of heat transfer plate A1, thewidth is allowed to be, for example, 7 mm.

When heat transfer plates A1 and heat transfer plates B2 are laminatedalternately, as shown in FIG. 3, molding is carried out so that the topsurface of outer peripheral rib A12 a of heat transfer plate A1 isbrought into close contact with outer peripheral rib A12 b of heattransfer plate B2 laminated in the upper part and the top surface ofouter peripheral rib A12 b of heat transfer plate B2 is brought intoclose contact with outer peripheral rib A 12 a of heat transfer plate A1laminated in the upper part. As a result, outer surface and the innersurface of the outer side surfaces of adjacent outer peripheral ribs A12are brought into close contact with each other. Thus, air flow passagesA3 and air flow passages B4 are sealed at the portion of outerperipheral rib A12.

Furthermore, air flow passage rib 6 is formed so that the upper surfacethereof is brought into contact with the heat transfer plate laminatedin the upper part. Air flow passages 6 maintain the heights of air flowpassages of air flow passage A3 and air flow passage B4. The height ofthe air flow passage is designed in terms of performance such asair-flow resistance of a heat exchanger and a molding property, and thelike.

Furthermore, as shown in FIG. 4, at the inlets and outlets of the airflow passages, molding is carried out so that in the portion of theinlets and outlets of air flow passages, the inner surface of groove B16is brought into close contact with the outer surface of groove A8 of theheat transfer plate laminated in the upper part, the top surface ofouter peripheral rib B13 is brought into close contact with the transferplate laminated in the upper part, one side surface 10 a of the pair ofside surfaces 10 of protrusion 9 that is parallel to air flow passageend surface 7 is brought into close contact with the inner surface ofthe outer side surface of outer peripheral rib B13 of the heat transferplate laminated in the upper part, another side surface 10 b is broughtinto close contact with the side surface of groove B16 of the heattransfer plate laminated in the upper part, top surface 11 of protrusion9 is brought into close contact with the rear surface of the top surfaceof outer peripheral rib B13 of the heat transfer plate laminated in theupper part, and the outer side surface of the outer peripheral rib B13is brought into close contact with the inner surface of the air flowpassage end surface of the heat transfer plate laminated in the upperpart. As a result, air flow passage A3 and air flow passage B4 aresealed with each other at the portion of the inlets and outlets.Furthermore, dislocation of the laminated heat transfer plates isprevented and poisoning is carried out when heat transfer plates arelaminated.

Furthermore, as shown in FIGS. 5 and 6, in the corner portion in whichouter peripheral rib B13 of heat transfer plate A1 and outer peripheralrib B 13 of heat transfer plate B2 intersect each outer, grooves B13provided on the upper surface of outer peripheral ribs B13 alsointersect each other. Molding is carried out so that the top surface ofouter peripheral rib B13 is brought into contact with groove B16 of theheat transfer plate laminated on the upper surface. Thus, deformation inthe laminating direction of the heat transfer plates in the cornerportion where outer peripheral ribs B13 intersect each other and thedeterioration due to the deformation in the sealing property isprevented.

Furthermore, as shown in FIGS. 7 and 8, on both ends of air flow passageA3 and air flow passage B4, molding is carried out so that in a cornerportion where the inlets and outlets of air flow passage A3 are adjacentto the inlets and outlets of air flow passage B4, the end surface ofouter peripheral rib B13 is brought into close contact with the innersurface of air flow passage end surface cover 15 a of the heat transferplate laminated in the upper part, and in a corner portion where theinlets and outlets of air flow passage A3 or air flow passage B4 isadjacent to outer peripheral rib A12, the end surface of outerperipheral rib A12 is brought into close contact with the inner surfaceof air flow passage end surface cover 15 b of the heat transfer platelaminated in the upper part. Thus, the sealing property on both ends ofair flow passage A3 and air flow passage B4 is secured.

The above-mentioned configuration enables a heat exchanger to beprovided, in which the sealing property of air flow passage A3 and airflow passage A4 is high, positioning can be carried out easily when heattransfer plates A1 and heat transfer plates B2 are laminated, air flowpassage ribs 6, protrusions 9, outer peripheral ribs A12 and outerperipheral ribs B13 are molded into a hollow convex shape by using onesheet of polystyrene sheet by vacuum molding process, thus reducing theweight and the amount of materials to be cast, a recycling property isimproved because the heat exchanger is configured by a single material,i.e., polystyrene that is a material of heat transfer plate A3 and heattransfer plate B4, and heat exchanging efficiency is improved becausefluid is also flown into the inner surfaces of hollow shaped air flowpassage rib 6 and heat exchange is carried out also in air flow passageribs 6.

In this Example, as a material for a heat transfer plate, a polystyrenesheet was used, and integration molding was carried out by vacuummolding. However, examples of the material may include a thermoplasticresin film of ABS, polypropylene, polyethylene, and the like, a thinmetal plate of aluminum, and the like, or a paper material having a heattransfer property and moisture permeability, a microporous resin film,and a paper material in which resin is contained, and the like.Furthermore, a heat transfer plate may be integrated by other moldingmethod such as pressure molding, extra high pressure molding, pressmolding, and the like, and also in such a case, the same effect can beobtained.

Furthermore, the dimension value and the number of each portion aredescribed as an example, and they are not particularly limited thereto.The same effect can be obtained even when they are appropriatelydesigned in terms of performance of a heat exchanger, for example,air-flow resistance, heat exchanging efficiency, etc., and a moldingprocess property, and the like.

A polystyrene sheet was used as a sheet material and the thicknessthereof was 0.2 mm. However, it is preferable that the thickness of thesheet material is in a range of 0.05 to 0.5 mm.

The thickness of not more than 0.05 mm makes a sheet material to beeasily damaged such as broken etc. when convex and concave portions areformed and when a heat transfer plate after molding is treated, andmakes it difficult to be treated because the molded heat transfer plateis less hard. While, the thickness of more than 5 mm deteriorates theheat transfer property.

The thinner the sheet thickness becomes, the higher the heat transferproperty tends to be and the lower the moldability tends to be. On thecontrary, the larger the sheet thickness becomes, the lower the heattransfer property tends to be.

Therefore, in order to satisfy the moldability and heat transferproperty, the thickness of the sheet material for use is preferably in arange of 0.05 to 0.5 mm and the most preferably in a range of 0.15 to0.25 mm.

EXAMPLE 2

Hereinafter, Example 2 of the present invention is described withreference to FIGS. 9, 10, 11, 12, 13 and 14.

The same members as those in Example 1 are designated with the samereference numbers and regarded as having the same effects, and thereforedetailed description thereof is omitted herein.

FIG. 9 is a schematic perspective view showing a vacuum molding die ofheat transfer plate A1 and heat transfer plate B2 of a heat exchangerused in this Example; FIG. 10 is a schematic enlarged perspective viewshowing a vacuum molded product of pair of heat transfer plate A1 andheat transfer plate B2; FIG. 11 is a schematic sectional view showingair flow passage opening portion 14; FIG. 12 is a schematic perspectiveview showing a method of cutting pair of heat transfer plate A1 and heattransfer plate B2; and FIG. 13 is a schematic sectional view showing acutting position of air flow passage opening portion 14 of the heattransfer plate.

As shown in FIG. 9, vacuum molding die 17 includes molding die portion17 a of heat transfer plate A1 and molding die portion 17 b of heattransfer plate B2. In a portion in which air flow passage openingportion 14 is formed on the outer side surface of outer peripheral ribsB13 of molding die portion 17 a of heat transfer plate A1 and moldingdie portion 17 b of heat transfer plate B2, rectangular shaped moldingdie portion 18 having a cross-sectional shape equal to that of air flowpassage opening portion 14, for example, rectangular shaped molding dieportion 18 having a height of 1.8 mm and a width of 160 mm isintegrated. Vacuum molding die 17 includes molding die portion 17 a ofheat transfer plate A1 and molding die portion 17 b of heat transferplate B2 in a way in which the outer side surfaces of the respectiveouter peripheral ribs B13 are facing each other and rectangular shapedmolding die portion 18 is connected and integrated to the respectivefacing side surfaces of outer peripheral rib B13. One vacuum molding dieportion 17 is provided with three sets of pair of molding die portions17 a of heat transfer plate A1 and molding die portions 17 b of heattransfer plate B2.

FIG. 10 shows one polystyrene sheet that was vacuum molded by usingvacuum molding die 17, which shows a molded product of heat transferplate A 1 and heat transfer plate B2. Actually, three sets of the heattransfer plates A and the heat transfer plates B are formed, however, apair of heat transfer plate A1 and heat transfer plate B2 are shown forsimplification.

Heat transfer plate A1 and heat transfer plate B2 are integration moldedwith opening formation portion 19 molded in a hollow shape by usingrectangular molding die portion 18 in which the outer side surfaces ofouter peripheral rib B13 face each other. As shown in FIG. 11, openingformation portion 19 is continuously integrated with the outer sidesurface of outer peripheral ribs B13 so as to form space having the sameheight as that of air flow passage opening portion 14 of the outer sidesurfaces of outer peripheral rib B13.

As shown in FIG. 12, cutting die 20 provided with a punch cutter havinga shape that is equal to that of the outer peripheral shape of therespective heat transfer plates is pressed to the outer peripheral edgeportion of heat transfer plate A1 and the outer peripheral edge portionof heat transfer plate B2, thereby cutting heat transfer plate A1 andheat transfer plate B2.

When heat transfer plate A1 and heat transfer plate B2 are cut, as shownin FIG. 13, opening formation portion 19 continuously integrated with anouter side surface of outer peripheral rib B13 is cut from the outerside surface of outer peripheral rib B13 by using cutting die 20. On theouter side surfaces of outer peripheral rib B13, air flow passageopening portion 14 is formed.

According to the above-mentioned Example, since the outer peripheries ofheat transfer plate A1 and heat transfer plate B2 are cut in apredetermined dimension and at the same time, air flow passage openingportion 14 is formed on the outer side surface of outer peripheral ribB13, it is possible to obtain a heat exchanger with high productiveefficiency.

In this Example, vacuum molding die 17 was provided with three sets ofmolding die portions 17 a of the heat transfer plate A and molding dieportions 17B of the heat transfer plate B, but the number of the sets isdescribed as an example. The same effect can be obtained even whendesign is carried out by selecting a value that is not particularlylimited thereto.

Furthermore, the dimension value and the number of each portion aredescribed as an example, and they are not particularly limited thereto.The same effect can be obtained even when they are appropriatelydesigned in terms of performance of a heat exchanger, for example,air-flow resistance, heat exchanging efficiency, etc., and a moldingprocess property, and the like.

EXAMPLE 3

Next, Example 3 of the present invention is described with reference toFIGS. 14 and 15.

The same members as those in Examples 1 and 2 are designated with thesame reference numbers and regarded as having the same effects, andtherefore detailed description thereof is omitted herein.

FIG. 14 is a schematic perspective view showing a heat exchanger used inthis Example in which corer portions are thermally welded; and FIG. 15is a schematic perspective view showing a thermal welding apparatusthereof.

As shown in FIG. 14, heat exchanger 21 is obtained by laminating apredetermined number of heat transfer plates A1 and heat transfer platesB2 alternately, for example, laminating 61 sheets each of heat transferplates A1 and heat transfer plates B2 alternately with heat transferplate A1 disposed at the bottom, and thermally welding the outer sidesurfaces of the laminated adjacent heat transfer plates at six cornerportions.

FIG. 15 shows thermal welding apparatus 22, including press plate 24which suppresses dislocation in the laminating direction of sheet block23 obtained by laminating 61 sheets each of heat transfer plates A1 andheat transfer plates B2 alternately with heat transfer plate A1 disposedat the bottom and regulates the height of laminated sheet block 23, forexample, regulates it to 280 mm; support plate 25 which suppressesdislocation in the horizontal direction of the heat transfer platesconstituting sheet block 23 and has a shape corresponding to the outerside surface on which the inlets and outlets of air flow passages A3 andair flow passages B4 of the heat transfer plate are formed and the outerside surface of outer peripheral rib A12; heater blocks 26 a and 26 bwhich are thermal welding means for thermally welding the corner portionof the adjacent inlet and outlet portions of air flow passages of sheetblock 23 fixed by press plate 24 and support plate 25 and which have awelding surface formed to have the width equal to that of the endsurfaces of air flow passage end surface cover 15 a and outer peripheralrib B13; and heater blocks 26 c and 26 d which are thermal welding meansfor thermally welding the corner portions of both ends of outerperipheral rib B13 and which have a welding surface formed to have thewidth equal to that of the end surface of air flow passage end surfacecover 15 b and outer peripheral rib A12. Heater blocks 26 a to 26 d areprovided with cylindrical electric heaters 27 therein.

On thermal welding apparatus 22, sheet block 23 is disposed in closecontact with support plate 25. Thereafter, by pressing press plate 24 tothe top surface of sheet block 23, sheet block 23 is fixed to thermalwelding apparatus 22.

By pressing heater blocks 26 a, 26 b, 26 c and 26 d whose surfacetemperatures were set to, for example, 140° C. to sheet block 23 fixedto thermal welding apparatus 22 for, for example, five seconds, fourcorners of sheet block 23 are thermally welded. Then, press plate 24 isonce removed from sheet block 23, the direction in which sheet block 23is disposed is rotated by 180°. Then, sheet block 23 is fixed by pressplate 24 and support plate 25 again and heater blocks 26 c and 26 d arepressed to the corner portions of sheet block 23. Thereby, heatexchanger 21 is manufactured, in which six corer portions of sheet block23 are thermally welded over the entire length in the laminatingdirection.

According to the above-mentioned Example, in the laminated adjacent heattransfer plates, air flow passage end surface cover 15 and the endsurface of outer peripheral rib A12, air flow passage end surface cover15 and the end surface of outer peripheral rib B13, air flow passage endsurface 7 and the side surface of outer peripheral rib B13, and sidesurfaces of outer peripheral ribs A12 are thermally welded to be fixed.Thus, deterioration of the sealing property of the air flow passages dueto dislocation is prevented, and the sealing property is improved. Sinceadjacent portions to be thermally welded that are not present on thesame plane are thermally welded simultaneously, it is possible to obtaina heat exchanger with high productive efficiency.

In this Example, sheet block 23 is disposed to thermal welding apparatus22 in a way in which the heat transfer plates are laminated in thevertical direction. However, the same effect can be obtained even whensheet block 23 is disposed by using thermal welding apparatus 22 inwhich the heat transfer plates are laminated in the horizontaldirection. Furthermore, the number of heat transfer plates A1 and heattransfer plates B2 to be laminated to constitute sheet block 23 isdescribed as an example. The same effect can be obtained even when aheat exchanger is appropriately designed in terms of performance of theheat exchanger, for example, air-flow resistance, heat exchangingefficiency, and the like.

Furthermore, a heat transfer plate to be disposed at the bottom is notparticularly limited to heat transfer plate A1. The same effect can beobtained by laminating heat transfer plates with heat transfer plate Bdisposed at the bottom.

Furthermore, temperature, number and welding time of heater block 26 aredescribed as examples but they are not particularly limited to theexamples. The same effect can be obtained even when they are determinedso as to obtain an excellent welding state.

EXAMPLE 4

Next, Example 4 of the present invention is described with reference toFIGS. 16 and 17.

The same members as those in Examples 1, 2 and 3 are designated with thesame reference numbers and regarded as having the same effects, andtherefore detailed description thereof is omitted herein.

FIG. 16 is a schematic perspective view showing a heat exchanger used inthis Example in which surfaces on which the inlets and outlets of airflow passages A3 and air flow passages B4 are formed are thermallywelded; and FIG. 17 is a schematic perspective view showing a thermalwelding apparatus thereof.

As shown in FIG. 16, heat exchanger 21 is obtained by laminating apredetermined number of heat transfer plates A1 and heat transfer platesB2 alternately, for example, laminating 61 sheets each of heat transferplates A1 and heat transfer plates B2 alternately with heat transferplate A1 disposed at the bottom, and entire four surfaces on which theinlets and outlets of air flow passages A3 and air flow passages B4 areformed are thermally welded.

FIG. 17 shows thermal welding apparatus 22, including press plate 24which suppresses dislocation in the laminating direction of sheet block23 obtained by laminating 61 sheets each of heat transfer plates A1 andheat transfer plates B2 alternately with heat transfer plate A1 disposedat the bottom and regulates the height of laminated sheet block 23, forexample, regulates it to 280 mm; support plate 25 which suppressesdislocation in the horizontal direction of the heat transfer platesconstituting sheet block 23 and has a shape corresponding to the outerside surface on which the inlets and outlets of air flow passages A3 andair flow passages B4 of the heat transfer plate are formed; and heaterblock 26 as a thermal welding means for thermally welding adjacentsurfaces on which the inlets and outlets of air flow passages A3 and airflow passages B4 of sheet block 23 fixed by press plate 24 and supportplate 25 are formed. In heater block 26, both ends protrude from thesurface on which the inlets and outlets of air flow passages A3 and airflow passages B4 are formed, for example, protrude by 10 mm each; andthe top and bottom ends protrude in the vertical direction of sheetblock 23, for example, protrude by 10 mm each. Inside heater block 26, aplurality of, for example, five electric cylindrical electric heaters 27are provided.

On thermal welding apparatus 22, sheet block 23 is disposed in closecontact with support plate 25. Thereafter, by pressing press plate 24 tothe top surface of sheet block 23, sheet block 23 is fixed to thermalwelding apparatus 22.

By pressing heater block 26 whose surface temperature was set to, forexample, 140° C. to sheet block 23 fixed to thermal welding apparatus 22for, for example, five seconds, two adjacent surfaces on which theinlets and outlets of air flow passages A3 and air flow passages B4 ofsheet block 23 are formed are thermally welded simultaneously. Then,press plate 24 is once removed from sheet block 23, the direction inwhich sheet block 23 is disposed is rotated by 180°. Then, sheet block23 is fixed by press plate 24 and support plate 25 again, and heaterblock 26 is pressed to two adjacent surfaces on which the inlets andoutlets of air flow passages A3 and air flow passages B4 of sheet block23 are formed. Thereby, heat exchanger 21 is manufactured, in whichportions on which side surfaces of heat transfer plates A1 and heattransfer plates B2 are overlapped with each other are thermally weldedon entire four surfaces on which the inlets and outlets of air flowpassages A3 and air flow passages B4 of sheet block 23 are formed.

According to the above-mentioned Example, on the surface on which theinlets and outlets of air flow passages A3 and air flow passages B4 ofthe laminated adjacent heat transfer plates are formed, air flow passageend surface 7 and the side surface of outer peripheral rib B13, air flowpassage end surface cover 15 a and the end surface of outer peripheralrib B13, and air flow passage end surface cover 15 b and end surface ofouter peripheral rib A12 are welded by thermal welding. Thus, the outerside surface of outer peripheral ribs B13 of another air flow passagefacing the inlet and outlet portion of one air flow passage is sealed.Dislocation of heat transfer plates is suppressed so as to improve thesealing property of the air flow passage, and the sealing property ofthe air flow passage is prevented from being deteriorated due to thedislocation of the heat transfer plates. Since the sealing properties ofair flow passage A3 and air flow passage B4 are high and thermal weldingis carried out simultaneously with respect to the two adjacent surfaceson which the inlets and outlets of air flow passages A3 and air flowpassages B4 are formed and which are not present in the same plane.Thus, it is possible to obtain a heat exchanger with high productionefficiency.

In this Example, one heater block 26 was used. However, by configuringsupport plate 25 to have a planar shape that is brought into closecontact with the side surface of outer peripheral rib A12 of sheet block23 in which two heater blocks 26 are pressed in the opposite directionso as to allow heater block 26 to have functions of both a thermalwelding means and a supporting means of sheet block 23, entire foursurfaces on which the inlets and outlets of air flow passages A3 and airflow passages B4 are formed and which are not present on one plane canbe thermally welded simultaneously, thus productive efficiency can befurther enhanced. Furthermore, sheet block 23 is disposed to thermalwelding apparatus 22 in a way in which the heat transfer plates arelaminated in the vertical direction. However, the same effect can beobtained even when sheet block 23 is disposed by using thermal weldingapparatus 22 in which the heat transfer plates are laminated in thehorizontal direction.

Furthermore, the number of heat transfer plates A1 and heat transferplates B2 to be laminated to constitute sheet block 23 is described asan example. The same effect can be obtained even when a heat exchangeris appropriately designed in terms of performance of the heat exchanger,for example, air-flow resistance, heat exchanging efficiency, and thelike. Furthermore, a heat transfer plate to be disposed at the bottom isnot particularly limited to heat transfer plate A1. The same effect canbe obtained by laminating heat transfer plates with heat transfer plateB disposed at the bottom.

Furthermore, temperature, number and welding time of heater block 26 aredescribed as examples and they are not particularly limited to theexamples. The same effect can be obtained when they are determined so asto obtain an excellent welding state.

EXAMPLE 5

Next, Example 5 of the present invention is described with reference toFIGS. 18 and 19.

The same members as those in Examples 1, 2, 3 and 4 are designated withthe same reference numbers and regarded as having the same effects, andtherefore detailed description thereof is omitted herein.

FIG. 18 is a schematic perspective view showing a heat exchanger used inthis Example in which thermal welding is carried out to a front surfaceof the outer side surface; and FIG. 19 is a schematic perspective viewshowing a thermal welding apparatus thereof.

As shown in FIG. 18, heat exchanger 21 is produced by laminating apredetermined number of heat transfer plates A1 and heat transfer platesB2 alternately, for example, laminating 61 sheets each of heat transferplates A1 and heat transfer plates B2 alternately with heat transferplate A1 disposed at the bottom and welding entire six surfaces, i.e.,the surfaces on which the inlets and outlets of air flow passages A3 andair flow passages B4 are formed and the outer side surfaces of outerperipheral ribs A12 by thermal welding.

FIG. 19 shows thermal welding apparatus 22, including press plate 24which suppresses dislocation in the laminating direction of sheet block23 obtained by laminating 61 sheets each of heat transfer plates A1 andheat transfer plates B2 alternately with heat transfer plate A1 disposedat the bottom and regulates the height of laminated sheet block 23, forexample, regulates it to 280 mm; support plate 25 which suppressesdislocation in the horizontal direction of the heat transfer platesconstituting sheet block 23 and has a shape corresponding to the outerside surface on which the inlets and outlets of air flow passages A3 andair flow passages B4 of the heat transfer plate are formed and the outerside surface of outer peripheral rib A12; and heater block 26 as athermal welding means for thermally welding the surface on which theinlets and outlets of air flow passages A3 and air flow passages B4 areformed and the outer side surface of the outer peripheral rib A12,facing the surface that is brought into close contact with support plate25 of sheet block 23 fixed by press plate 24 and support plate 25.Heater block 26 has a thermally welding surface corresponding to thesurface on which the inlets and outlets of air flow passages A3 and airflow passages B4 are formed and the outer side surface of outerperipheral ribs A12. In heater block 26, both ends protrude from thesurface on which the inlets and outlets of air flow passages A3 and airflow passages B4 are formed, for example, protrude by 10 mm each; andthe top and bottom ends protrude in the vertical direction of sheetblock 23, for example, protrude by 10 mm each. Inside heater block 26, aplurality of, for example, seven electric cylindrical electric heaters27 are provided.

To thermal welding apparatus 22, sheet block 23 is disposed in closecontact with support plate 25. Thereafter, by pressing press plate 24 tothe upper surface of sheet block 23, sheet block 23 is fixed to thermalwelding apparatus 22.

By pressing heater block 26 whose surface temperature was set to, forexample, 140° C. to sheet block 23 fixed to thermal welding apparatus 22for, for example, five seconds, the outer side surface of outerperipheral rib A12 of sheet block 23 and two surfaces which are adjacentto outer peripheral rib A12 and on which the inlets and outlets of airflow passages A3 and air flow passages B4 are formed, that is, threesurfaces in total are thermally welded simultaneously. Then, press plate24 is once removed from sheet block 23, the direction in which sheetblock 23 is set is rotated by 180°. Then, sheet block 23 is fixed bypress plate 24 and support plate 25 again, and heater block 26 ispressed to sheet block 23. Thereby, heat exchanger 21 is manufactured,in which portions on which side surfaces of heat transfer plates A1 andheat transfer plates B2 are overlapped with each other are thermallywelded on entire six surfaces of sheet block 23 including the outer sidesurfaces of outer peripheral ribs A12 of sheet block 23 and the surfaceson which the inlets and outlets of air flow passages A3 and air flowpassages B4 are formed.

According to the above-mentioned Example, on the surface on which theinlets and outlets of air flow passages A3 and air flow passages B4 areformed of laminated adjacent heat transfer plates, air flow passage endsurface 7 and the side surface of outer peripheral rib B13, air flowpassage end surface cover 15 a and the end surface of outer peripheralrib B13, and air flow passage end surface cover 15 b and the end surfaceof outer peripheral rib A12 are welded by heater block 26. Thus, theouter side surfaces of outer peripheral ribs B13 at another side of airflow passage facing the inlet and outlet portions of one side of airflow passages are sealed. On the outer side surfaces of outer peripheralribs A12 of the laminated adjacent heat transfer plates, outer sidesurfaces of outer peripheral rib A12 are thermally welded by heaterblock 26. Thereby, the outer peripheral portions of entire air flowpassages are sealed. Furthermore, dislocation of heat transfer plates issuppressed and the sealing property of air flow passages is improved.The sealing property of the air flow passage is prevented from beingdeteriorated due to the dislocation of the heat transfer plates. Thesealing properties of air flow passage A3 and air flow passage B4 arehigh, the outer side surface of outer peripheral rib A12 and the twoadjacent surfaces on which the inlets and outlets of air flow passagesA3 and air flow passages B4 are formed, that is, three surfaces intotal, which are not present in the same plane, are thermally weldedsimultaneously. Thus, it is possible to obtain a heat exchanger withhigh production efficiency.

Note here that sheet block 23 is disposed to thermal welding apparatus22 in a way in which the heat transfer plates are laminated in avertical direction. However, the same effect can be obtained even whensheet block 23 is disposed by using thermal welding apparatus 22 inwhich the heat transfer plates are laminated in a horizontal direction.

Furthermore, the number of heat transfer plates A1 and heat transferplates B2 to be laminated to constitute sheet block 23 is described asan example. The same effect can be obtained even when a heat exchangeris appropriately designed in terms of performance of the heat exchanger,for example, air-flow resistance, heat exchanging efficiency, and thelike. Furthermore, a heat transfer plate to be disposed at the bottom isnot particularly limited to heat transfer plate A1. The same effect canbe obtained by laminating heat transfer plates with heat transfer plateB disposed at the bottom.

Furthermore, temperature, number and welding time of heater block 26 aredescribed as examples but they are not particularly limited to theexamples. The same effect can be obtained even when they are determinedso as to obtain an excellent welding state.

EXAMPLE 6

Next, Example 6 of the present invention is described with reference toFIGS. 20 and 21.

The same members as those in Examples 1, 2, 3, 4 and 5 are designatedwith the same reference numbers and regarded as having the same effects,and therefore detailed description thereof is omitted herein.

FIG. 20 is a schematic perspective view showing a first process of athermal welding apparatus in accordance with this Example; and FIG. 21is a schematic perspective view showing the second process thereof.

As shown in FIG. 20, thermal welding apparatus 22 includes press plate24 which suppresses dislocation in the laminating direction of sheetblock 23 obtained by laminating a predetermined number of heat transferplates A1 and heat transfer plates B2 alternately, for example,laminating 61 sheets each of heat transfer plates A1 and heat transferplates B2 alternately with heat transfer plate A1 disposed at the bottomand regulates the height of laminated sheet block 23, for example,regulates it to 280 mm; and support plate 25 which suppressesdislocation in the horizontal direction of the heat transfer platesconstituting sheet block 23 and which has a shape corresponding to theouter side surface on which the inlets and outlets of air flow passagesA3 and air flow passages B4 are formed and the outer side surface ofouter peripheral rib A12 of the heat transfer plates; heater blocks 26 aas a thermal welding means for thermally welding the outer side surfaceof outer peripheral rib A12 facing the surface that is brought intoclose contact with support plate 25 of sheet block 23 fixed by pressplate 24 and support plate 25; and blocks 26 b and 26 c as thermalwelding means for thermally welding two surfaces on which the inlets andoutlets of air flow passages A3 and air flow passages B4 are formedfacing the surface that is brought into close contact with support plate25 of sheet block 23 fixed by press plate 24 and support plate 25.Heater block 26 a has a shape in which thermal welding surface protrudesto positions capable of thermally welding air flow passage end surfacecover 15 b for the surface, which are adjacent to the both ends thereof,on which the inlets and outlets of air flow passages A3 and air flowpassages B4 are formed. Each of heater block 26 b and 26 c has a thermalwelding surface protruding in the direction of the adjacent outerperipheral rib A12 and capable of thermally welding a part of the outerside surface of adjacent outer peripheral rib A12, for example, aposition that is 10 mm from the corner at one end. At another end, eachof heater block 26 b and 26 c has a shape protruding from the surface onwhich the inlets and outlets of air flow passages A3 and air flowpassages B4 are formed, for example, protruding by 10 mm each. The upperand lower ends of heater blocks 26 a, 26 b and 26 c protrude in thevertical direction of sheet block 23, for example, protrude by 10 mmeach. Heater blocks 26 a, 26 b and 26 c include a plurality of, forexample, three cylindrical electric heaters 27 inside, respectively.

On thermal welding apparatus 22, sheet block 23 is disposed in closecontact with support plate 25. Thereafter, by pressing press plate 24 tothe top surface of sheet block 23, sheet block 23 is fixed to thermalwelding apparatus 22.

As a first process of thermal welding, heater block 26 a whose surfacetemperature was set to, for example, 140° C. is vertically pressed tothe side surface of outer peripheral ribs A12 of sheet block 23 fixed tothermal welding apparatus 22 for, for example, five seconds, air flowpassage end surface cover 15 b provided on outer side surface ofperipheral rib A12 and the surface which is adjacent to the outer sidesurface of the outer peripheral rib A12 and on which air flow passage A3and air flow passage B4 are formed and the end surface of outerperipheral rib A12 are thermally welded in sheet block 23. Thereafter,the heater block 26 a is removed from sheet block 23. Then, as a secondprocess, as shown in FIG. 21, by vertically pressing heater blocks 26 band 26 c whose surface temperatures were set to, for example, 130° C. torespective surfaces on which the inlets and outlets of air flow passagesA3 and air flow passages B4 of sheet block 23 are formed for, forexample, three seconds, the respective surfaces on which the inlets andoutlets of air flow passages A3 and air flow passages B4 are formed anda corner portion between the respective surfaces on which the inlets andoutlets of air flow passages A3 and air flow passages B4 are formed andouter peripheral ribs A12 are thermally welded. With the first andsecond process, the outer side surface of outer peripheral ribs A12facing the surface that is brought into close contact with support plate25 and two surfaces on which the inlets and outlets of air flow passagesA3 and air flow passages B4 are formed, i.e., three surfaces in totalare thermally welded.

Then, press plate 24 is once removed from sheet block 23, the directionin which sheet block 23 is set is rotated by 180°. Then, sheet block 23is fixed by press plate 24 and support plate 25 again. Similar to thefirst process and second process, as a third process of thermal welding,by vertically pressing heater block 26 a to the side surface of outerperipheral ribs A12 of sheet block 23 fixed to thermal welding apparatus22, air flow passage end surface cover 15 b provided on outer sidesurface of peripheral rib A12 and the surface which is adjacent to theouter side surface of the outer peripheral rib A12 and on which air flowpassage A3 and air flow passage B4 are formed and the end surface ofouter peripheral rib A12 are thermally welded in sheet block 23.Thereafter, the heater block 26 a is removed from sheet block 23. Then,as a fourth process, by vertically pressing heater blocks 26 b and 26 cto the respective surfaces on which the inlets and outlets of air flowpassages A3 and air flow passages B4 of sheet block 23 are formed, therespective surfaces on which the inlets and outlets of air flow passagesA3 and air flow passages B4 are formed and a corner portion between therespective surfaces on which the inlets and outlets of air flow passagesA3 and air flow passages B4 are formed and outer peripheral rib A12 arethermally welded. With the third process and fourth process, the outerside surface of outer peripheral rib A12 facing a surface that isbrought into close contact with support plate 25 and two surfaces onwhich the inlets and outlets of air flow passages A3 and air flowpassages B4 are formed, that is, three surfaces in total are thermallywelded. With the first, second, third and fourth processes, heatexchanger 21 is manufactured in which the outer side surface of outerperipheral ribs A12 and the surface on which the inlets and outlets ofair flow passages A3 and air flow passages B4 of sheet block 23 areformed, that is, entire six surfaces, portions in which side surfaces ofheat transfer plate A1 and heat transfer plate B2 are overlapped witheach other are thermally welded.

According to the above-mentioned Example, the corner portions of thesurfaces on which the inlets and outlets of air flow passages A3 and airflow passages B4 are formed and outer peripheral rib A12 are thermallywelded twice by using heater blocks 26 a, 26 b or 26 c. Thereby, it ispossible to reliably carry out thermal welding of the corner portionthat cannot be thermally welded easily. When thermal welding is carriedout by vertically pressing heater blocks 26 a, 26 b and 26 c to athermally welded surface of sheet block 23, respectively, the sealingproperty of the portion in which the outer side surfaces of the heattransfer plates are overlapped with each other is enhanced, on thesurface on which the inlets and outlets of air flow passages A3 and airflow passages B4 are formed in the laminated adjacent heat transferplates, air flow passage end surface 7 and the side surface of outerperipheral rib B13, air flow passage end surface cover 15 a and the endsurface of outer peripheral rib B13, and air flow passage end surfacecover 15 b and the end surface of outer peripheral rib A12 are thermallywelded by heater blocks 26 b and 26 c. Thus, the outer side surfaces ofouter peripheral ribs B13 at another side of air flow passage facing theinlet and outlet portions of one side of air flow passages are sealed.On the outer side surface of outer peripheral ribs A12 of the laminatedadjacent heat transfer plates, outer side surfaces of outer peripheralribs A12 are thermally welded by heater block 26. Thereby entireperipheral portions of the air flow passages are sealed. Furthermore,dislocation of the heat transfer plates is suppressed so as to improvethe sealing property of the air flow passage. Thus, the sealing propertyof the air flow passage is prevented from being deteriorated due to thedislocation of the heat transfer plates. Thus, it is possible to obtaina heat exchanger with a high sealing property of air flow passage A3 andair flow passage B4.

Note here that the same effect can be obtained even when the order ofthe first process and second process and the order of the third processand fourth process in the thermal welding process are reverse.Furthermore, sheet block 23 is disposed to thermal welding apparatus 22in a way in which the heat transfer plates are laminated in the verticaldirection. However, the same effect can be obtained even when sheetblock 23 is disposed by using thermal welding apparatus 22 in which theheat transfer plates are laminated in the horizontal direction.

Furthermore, the number of heat transfer plates A1 and heat transferplates B2 to be laminated to constitute sheet block 23 is described asan example. The same effect can be obtained even when a heat exchangeris appropriately designed in terms of performance of the heat exchanger,for example, air-flow resistance, heat exchanging efficiency, and thelike. Furthermore, a heat transfer plate to be disposed at the bottom isnot particularly limited to heat transfer plate A1. The same effect canbe obtained by laminating heat transfer plates with heat transfer plateB disposed at the bottom.

Furthermore, temperature, number and welding time of heater block 26 aredescribed as examples but they are not particularly limited to theexamples. The same effect can be obtained even when they are determinedso as to obtain an excellent welding state.

EXAMPLE 7

Next, Example 7 of the present invention is described with reference toFIG. 22.

The same members as those in Examples 1, 2, 3, 4, 5 and 6 are designatedwith the same reference numbers and regarded as having the same effects,and therefore detailed description thereof is omitted herein.

FIG. 22 is a schematic perspective view showing a thermal weldingapparatus used in this Example.

As shown in FIG. 22, thermal welding apparatus 22 includes press plate24 which suppresses dislocation in the laminating direction of sheetblock 23 obtained by laminating a predetermined number of sheetsalternately, for example, laminating 61 sheets each of heat transferplates A1 and heat transfer plates B2 alternately with heat transferplate A1 disposed at the bottom and regulates the height of laminatedsheet block 23, for example, regulates it to 280 mm; support plate 25which suppresses dislocation in the horizontal direction of the heattransfer plates constituting sheet block 23 and which has a shapecorresponding to the outer side surface on which the inlets and outletsof air flow passages A3 and air flow passages B4 are formed and theouter side surface of outer peripheral ribs A12 of the heat transferplates; heater roller 28 a as a thermal welding means for thermallywelding the outer side surface of outer peripheral rib A12 facing thesurface that is brought into close contact with support plate 25 ofsheet block 23 fixed by press plate 24 and support plate 25; and heaterrollers 28 b and 28 c as a thermal welding means for thermally weldingtwo surfaces on which the inlets and outlets of air flow passages A3 andair flow passages B4 are formed and which face the surface that isbrought into close contact with support plate 25 of sheet block 23 fixedby press plate 24 and support plate 25. Heater rollers 28 a, 28 b and 28c are formed in length protruding from respective thermally weldedsurfaces of sheet block 23, for example, protruding by 15 mm each.

On thermal welding apparatus 22, sheet block 23 is disposed in closecontact with support plate 25. Thereafter, by pressing press plate 24 tothe top surface of sheet block 23, sheet block 23 is fixed to thermalwelding apparatus 22.

Thermal welding of the side surface of outer peripheral rib A12 iscarried out by pressing heater roller 28 a to the side surface of outerperipheral rib A12 of sheet block 23 that is fixed to thermal weldingapparatus 22 and moving while rotating it from an upper part to a lowerpart in the laminating direction. Thereafter, at predeterminedintervals, for example, at an interval of 30 mm, by pressing heaterrollers 28 b and 28 c to respective surfaces on which the inlets andoutlets of air flow passages A3 and air flow passages B4 are formed andmoving while rotating it from an upper part to a lower part in thelaminating direction, the respective surfaces on which the inlets andoutlets of air flow passages A3 and air flow passages B4 are formed andthe respective surfaces on which the inlets and outlets of air flowpassages A3 and air flow passages B4 are formed are thermally welded.Thus, the outer peripheral side surfaces of outer peripheral ribs A12and two surfaces on which the inlets and outlets of air flow passages A3and air flow passages B4 are formed, which face the surface that isbrought into close contact with support plate 25, three surfaces intotal are thermally welded.

Then, press plate 24 is once removed from sheet block 23, the directionin which sheet block 23 is set is rotated by 180°. Then, sheet block 23is fixed by press plate 24 and support plate 25 again. Thermal weldingof the side surface of outer peripheral rib A12 is carried out bypressing heater roller 28 a to the side surface of outer peripheral ribsA12 of sheet block 23 fixed to thermal welding apparatus 22, and movingwhile rotating it from an upper part to a lower part in the laminatingdirection. Thereafter, at predetermined intervals, by pressing heaterrollers 28 b and 28 c to respective surfaces on which the inlets andoutlets of air flow passages A3 and air flow passages B4 are formed andmoving while rotating it from an upper part to a lower part in thelaminating direction, the respective surfaces on which the inlets andoutlets of air flow passages A3 and air flow passages B4 are formed andthe respective surfaces on which the inlets and outlets of air flowpassages A3 and air flow passages B4 are formed are thermally welded.Thus, the outer peripheral side surfaces of outer peripheral ribs A12and two surfaces on which the inlets and outlets of air flow passages A3and air flow passages B4 are formed, which face the surface that isbrought into close contact with support plate 25, three surfaces intotal are thermally welded. Heat exchanger 21 is manufactured in which aportion in which side surfaces of heat transfer plate A1 and heattransfer plate B2 are overlapped with each other are thermally welded onthe outer side surface of outer peripheral ribs A12 of sheet block 23and surfaces on which the inlets and outlets of air flow passages A3 andair flow passages B4 are formed, that is, entire six surfaces arethermally welded

According to the above-mentioned Example, since heater roller 28 moveswhile rotating from an upper part to a lower part along the laminatingdirection of the heat transfer plates and the direction in which theheater roller is rotated and the direction in which the outer peripheralside surfaces of the heat transfer plates are folded are the same,occurrence of warp or folding of the outer peripheral side surface ofthe heat transfer plates at the time of thermal welding is prevented.Furthermore, since the direction of level difference between a cutportion of the outer side surface of the heat transfer plate and theouter peripheral side surface of the heat transfer plate located in thelower part, which occurs due to overlapping of the outer side surfacesof the heat transfer plates, is substantially parallel to heater roller28, defective thermal welding due to the level difference in the outerside surfaces of the heat transfer plates is prevented. Thus, a heatexchanger with a high sealing property can be obtained.

In this Example, sheet block 23 is disposed to thermal welding apparatus22 in a way in which the heat transfer plates are laminated in thevertical direction. However, the same effect can be obtained even whensheet block 23 is disposed by using thermal welding apparatus 22 inwhich the heat transfer plates are laminated in the horizontaldirection.

Furthermore, the number of heat transfer plates A1 and heat transferplates B2 to be laminated to constitute sheet block 23 is described asan example. The same effect can be obtained even when a heat exchangeris appropriately designed in terms of performance of the heat exchanger,for example, air-flow resistance, heat exchanging efficiency, and thelike. Furthermore, a heat transfer plate to be disposed at the bottom isnot particularly limited to heat transfer plate A1. The same effect canbe obtained by laminating heat transfer plates with heat transfer plateB disposed at the bottom.

EXAMPLE 8

Next, Example 8 of the present invention is described with reference toFIGS. 23 and 24.

The same members as those in Examples 1, 2, 3, 4, 5, 6 and 7 aredesignated with the same reference numbers and regarded as having thesame effects, and therefore detailed description thereof is omittedherein.

FIG. 23 is a schematic perspective view showing a heat exchanger used inthis Example; and FIG. 24 is a schematic exploded view thereof.

As shown in FIGS. 23 and 24, heat exchanger 21 includes urethane foamsheets 29 as an elastic body at both ends in the laminating direction ofsheet block 23 obtained by laminating a predetermined number of heattransfer plates A1 and heat transfer plates B2 alternately, for example,laminating 61 sheets each of heat transfer plates A1 and heat transferplates B2 alternately with heat transfer plate A1 disposed at thebottom. Urethane foam sheet 29 has a thickness of, for example, 5 mm andhas a hexagonal shape that is the same as the planar shape of heattransfer plate A1 and heat transfer plate B2. Heat exchanger 21 includestop plate 30 and bottom plate 31 as the first end surface membersprovided at both ends in the laminating direction of sheet blocks 23 viaurethane foam sheets 29. Top plate 30 and bottom plate 31 include sidesurface covers 32 covering the outer side surfaces of urethane foamsheet 29 and heat transfer plate A1 or heat transfer plate B2 disposedat both ends of and sheet block 23. Heat exchanger 21 includes sideplates 33 a and 33 b as support members for connecting top plate 30 andbottom plate 31 at both surfaces of the side surfaces of outerperipheral ribs A12 of sheet block 23. Both ends of side plates 33 a and33 b are provided with folded connection portions 34 between top plate30 and bottom plate 31. Connection portions 34 provided at top plate 30and bottom plate 31 as well as side plate 33 a and side plate 33 b arefastened with screw 35. The upper surface of top plate 30 is providedwith handle 36 a. Side plate 33 a is provided with handle 36 b folded ina rectangular U shape in the direction that is opposite to sheet block23. Top plate 30, bottom plate 31 and side plate 33 are manufactured bya thin iron plate having a thickness of, for example, 0.5 mm.

Handle 36 a is provided in the direction perpendicular to the directionin which heat transfer plates are laminated and handle 36 b is providedin the direction perpendicular to the laminating direction, that is, ona side surface of outer peripheral ribs A12. Thereby, a heat exchangercan be attached and detached to/from equipment in the laminatingdirection of heat transfer plates and in the direction of the sidesurfaces of outer peripheral ribs A12. With side surface covers 32provided on top plate 30 and bottom plate 31 and urethane sheets 29, thesealing of air flow passages A3 and air flow passages B 4 is carried outbetween top plate 30, bottom plate 31 and sheet block 23. Furthermore,with side surface cover 32, positioning can be carried out easily whenurethane sheet 29, sheet block 23, top plate 30 and bottom plate 31 areassembled. By disassembling top plate 30, bottom plate 31 and side plate33, sheet block 23 can be replaced, and urethane foam sheet 29, topplate 30, bottom plate 31 and side plate 33 and screw 35 can be reused.Since sheet block 23 is also composed of only polystyrene, a heatexchanger with a high recycling property can be obtained.

Note here that in this Example, handle 36 b was formed by folding sideplate 31 a in a rectangular U-shape. As shown in FIGS. 25 and 26,however, the same effect can be obtained even when a shape in which theplate protrudes in the direction of the inlets and outlets of air flowpassages A3 or air flow passages B4. Urethane sheet 29 was used as anelastic body. However, the same effect can be obtained even when foam ofother resin such as ethylene foam, styrene foam, and the like, or rubberfoam is used. The thickness thereof is described as an example and isnot particularly limited as long as it can secure the sealing of airflow passages A3 and air flow passages B4 between top plate 30, bottom31 and sheet block 23.

Urethane sheet 29 was made in a hexagonal shape that is the same asplanar shape of heat transfer plate A1 and heat transfer plate B2.However, the same effect can be obtained by making urethane sheet 29 inan annular shape in which the central part is punched out. Furthermore,top plate 30, bottom plate 31 and side plate 33 were made of sheetmetal, however, the same effect can be obtained even when other sheetmetal such as aluminum or resin is used.

Furthermore, when the direction in which heat exchanger 21 is attachedand detached is limited, handle 36 may be provided only in the directionin which heat exchanger 21 is attached and detached.

Furthermore, the number of heat transfer plates A1 and heat transferplates B2 to be laminated to constitute sheet block 23 is described asan example. The same effect can be obtained even when a heat exchangeris appropriately designed in terms of performance of the heat exchanger,for example, air-flow resistance, heat exchanging efficiency, and thelike. Furthermore, a heat transfer plate to be disposed at the bottom isnot particularly limited to heat transfer plate A1. The same effect canbe obtained by laminating heat transfer plates with heat transfer plateB disposed at the bottom.

EXAMPLE 9

Next, Example 9 of the present invention is described with reference toFIGS. 27 and 28.

The same members as those in Examples 1, 2, 3, 4, 5, 6, 7 and 8 aredesignated with the same reference numbers and regarded as having thesame effects, and therefore detailed description thereof is omittedherein.

FIG. 27 is a schematic perspective view showing a heat exchanger used inthis Example; and FIG. 28 is a schematic exploded view thereof.

As shown in FIGS. 27 and 28, heat exchanger 21 includes urethane foamsheets 29 as an elastic body at both ends in the laminating direction ofsheet block 23 obtained by laminating a predetermined number of heattransfer plates A1 and heat transfer plates B2 alternately, for example,laminating 61 sheets each of heat transfer plates A1 and heat transferplates B2 alternately with heat transfer plate A1 disposed at thebottom. Urethane foam sheet 29 has a thickness of, for example, 5 mm andhas a hexagonal shape that is the same as planar shapes of heat transferplate A1 and heat transfer plate B2. Heat exchanger 21 includes topplate 30 and bottom plate 31 as the first end surface members viaurethane foam sheets 29 at both ends in the laminating direction ofsheet blocks 23. Top plate 30 and bottom plate 31 include side surfacecovers 32 covering the outer side surfaces of urethane foam sheet 29 andheat transfer plate A1 and heat transfer plate B2 disposed at both endsof and sheet block 23. On one side of the side surfaces of outerperipheral rib A12 of sheet block 23, side plate 33 a that is a supportmember continuing to top plate 30 and side plate 33 b continuing tobottom plate 31 are provided, and side surface 33 a and side surface 33b are fastened by screw 35 in a connection portion formed by folding theends of side surface 33 a and side surface 33 b in a rectangular Ushape. On another side of the side surfaces of outer peripheral rib A12of sheet block 23, side plate 33 c continuing to top plate 30 and bottomplate 31 is provided. Top plate 30, bottom plate 31 and side plates 33a, 33 b and 33 c are manufactured by a thin iron plate having athickness of, for example, 0.5 mm.

Since rectangular U-shaped connection portion 34 that connects sideplate 33 a and side plate 33 b provided on the side surfaces of outerperipheral ribs A12 of sheet block 23 functions as also a handle of heatexchanger 21, a heat exchanger can be attached and detached to/fromequipment in the direction of the side surfaces of outer peripheral ribsA12. Since top plate 30, bottom plate 31, and side plates 33 a, 33 b and33 c are integrated with each other, assembling is easy. By removingscrew 35 that fastens side plate 33 a and side plate 33 b, sheet block23 can be replaced. Urethane foam sheet 29, top plate 30, bottom plate31, side plate 33 and screw 35 can be reused. Further, sheet block 23 iscomposed of only polystyrene, a heat exchanger with a high recyclingproperty can be obtained.

Note here that urethane sheet 29 was used as an elastic body. However,the same effect can be obtained even when foam of other resin such asethylene foam, styrene foam, and the like, or rubber foam is used. Thethickness thereof is described as an example and is not particularlylimited as long as it can secure the sealing of air flow passages A3 andair flow passages B4 between top plate 30, bottom 31 and sheet block 23.

Urethane sheet 29 was made in a hexagonal shape that is the same asplanar shape of heat transfer plate A1 and heat transfer plate B2.However, the same effect can be obtained by making urethane sheet 29 inan annular shape in which the central part is punched out. Furthermore,top plate 30, bottom plate 31 and side plate 33 were made of sheetmetal, however, the same effect can be obtained even when other sheetmetal such as aluminum or resin is used.

Furthermore, the number of heat transfer plates A1 and heat transferplates B2 to be laminated to constitute sheet block 23 is described asan example. The same effect can be obtained even when a heat exchangeris appropriately designed in terms of performance of the heat exchanger,for example, air-flow resistance, heat exchanging efficiency, and thelike. Furthermore, a heat transfer plate to be disposed at the bottom isnot particularly limited to heat transfer plate A1. The same effect canbe obtained by laminating heat transfer plates with heat transfer plateB disposed at the bottom.

EXAMPLE 10

Next, Example 10 of the present invention is described with reference toFIGS. 29 and 30.

The same members as those in Examples 1, 2, 3, 4, 5, 6, 7, 8 and 9 aredesignated with the same reference numbers and regarded as having thesame effects, and therefore detailed description thereof is omittedherein.

FIG. 29 is a schematic perspective view showing a heat exchanger used inthis Example; and FIG. 30 is a schematic exploded view thereof.

As shown in FIGS. 29 and 30, heat exchanger 21 includes resin band 37 asa band-like handle member along the both surfaces of the side surfacesof outer ribs A12 of sheet block 23 obtained by laminating apredetermined number of heat transfer plates A1 and heat transfer platesB2 alternately, for example, laminating 61 sheets each of heat transferplates A1 and heat transfer plates B2 alternately with heat transferplate A1 disposed at the bottom; and urethane foam sheets 29 as secondend surface members at both ends in the laminating direction of sheetblock 23. Urethane foam sheet 29 has a thickness of, for example, 10 mmand has a hexagonal shape that is the same as planar shapes of heattransfer plate A1 and heat transfer plate B2 and an adhesive agent isapplied to one side thereof. Resin band 37 is fixed to the heat transferplate at both ends in the laminating direction of sheet block 23 whenurethane foam sheet 29 is affixed.

Since by attaching urethane foam sheets 29 to the both ends of sheetblock 23 in the lamination direction, fixing of resin band 37 can becarried out simultaneously, a heat exchanger 21 can be manufactured withfewer man-hours. When heat exchanger 21 is mounted onto equipment,urethane foam sheet 29 can seal between the equipment and heat exchanger21 at the end surfaces in the laminating direction of the heat transferplates. Since resin band 37 is disposed on the outer side surfaces ofouter peripheral ribs A12, heat exchanger 21 can be attached anddetached in the direction of the side surfaces of outer peripheral ribsA12, and by peeling urethane foam sheet 29 from sheet block 23, sheetblock 23 is composed of only polystyrene that is a sheet material. Thus,a heat exchanger with a high recycling property can be obtained.

In this Example, resin band 37 has an annular structure. As shown inFIGS. 31 and 32, however, the same effect can be obtained even when ithas a shape of one band with both ends protruding to one surface of theside surfaces of outer peripheral rib A12 of sheet block 23. In thisExample, urethane sheet 29 was used as an elastic body. However, thesame effect can be obtained even when foam of other resin such asethylene foam, styrene foam, and the like, or rubber foam is used.

The thickness thereof is described as an example and is not particularlylimited as long as it can secure the sealing of air flow passage A3 andair flow passage B4 between equipment and heat exchanger 21.

Urethane sheet 29 was made in a hexagonal shape that is the same as aplanar shape of heat transfer plate A1 and heat transfer plate B2.However, the same effect can be obtained by making the planar shape inan annular shape in which the central part is punched out.

Furthermore, the number of heat transfer plates A1 and heat transferplates B2 to be laminated to constitute sheet block 23 is described asan example. The same effect can be obtained even when a heat exchangeris appropriately designed in terms of performance of the heat exchanger,for example, air-flow resistance, heat exchanging efficiency, and thelike. Furthermore, a heat transfer plate to be disposed at the bottom isnot particularly limited to heat transfer plate A1. The same effect canbe obtained by laminating heat transfer plates with heat transfer plateB disposed at the bottom.

EXAMPLE 11

Next, Example 11 of the present invention is described with reference toFIGS. 33 and 34.

The same members as those in Examples 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10are designated with the same reference numbers and regarded as havingthe same effects, and therefore detailed description thereof is omittedherein.

FIG. 33 is a schematic perspective view showing a heat exchanger used inthis Example; and FIG. 34 is a schematic exploded view thereof.

As shown in FIGS. 33 and 34, heat exchanger 21 includes resin band 37 asa band-like handle member along the both surfaces of side surface of theouter peripheral rib A12 of sheet block 23 obtained by laminating apredetermined number of heat transfer plates A1 and heat transfer platesB2 alternately, for example, laminating 61 sheets each of heat transferplates A1 and heat transfer plates B2 alternately with heat transferplate A1 disposed at the bottom; and urethane foam sheets 29 as secondend surface members at both ends in the laminating direction of sheetblock 23. Urethane foam sheet 29 has a thickness of, for example, 10 mmand has a hexagonal shape that is the same as a planar shape of heattransfer plate A1 and heat transfer plate B2 and an adhesive agent isapplied to one side thereof. Resin band 37 is fixed to the heat transferplate A1 that is located at the bottom when urethane foam sheet 29 isattached at a lower end surface in the laminating direction of sheetblock 23 and is disposed at the outside of urethane foam sheet 29 at anupper end surface.

With the above-mentioned configuration, since by attaching urethane foamsheets 29 to heat transfer plate A1 at the bottom, fixing of resin band37 can be carried out simultaneously, a heat exchanger can bemanufactured with fewer man-hours. When heat exchanger 21 is mountedonto equipment, urethane foam sheet 29 can seal between the equipmentand heat exchanger 21 at end surfaces in the laminating direction of theheat transfer plates. Since resin band 37 is disposed at the outside ofurethane sheet 29 affixed to the outer side surface and the uppersurface of outer peripheral rib A12, the heat exchanger can be attachedand detached both in the direction of the side surface of outerperipheral ribs A12 and in the laminating direction of heat transferplates. By peeling urethane foam sheet 29 from sheet block 23, sheetblock 23 is composed of only polystyrene that is a sheet material. Thus,a heat exchanger with a high recycling property can be obtained.

Note here that urethane sheet 29 was used as an elastic body. However,the same effect can be obtained even when foam of other resin such asethylene foam, styrene foam, and the like, or rubber foam is used.Urethane sheet 29 was made in a hexagonal shape that is the same as aplanar shape of heat transfer plate A1 and heat transfer plate B2.However, the same effect can be obtained by making the planar shape inan annular shape with the central part punched out.

The thickness thereof is described as an example and is not particularlylimited as long as it can secure the sealing of air flow passage A3 andair flow passage B4 between equipment and heat exchanger 21.

Urethane sheet 29 was made in a hexagonal shape that is the same as aplanar shape of heat transfer plate A1 and heat transfer plate B2.However, the same effect can be obtained by making the planar shape inan annular shape with the central part punched out.

Furthermore, the number of heat transfer plates A1 and heat transferplates B2 to be laminated to constitute sheet block 23 is described asan example. The same effect can be obtained even when a heat exchangeris appropriately designed in terms of performance of the heat exchanger,for example, air-flow resistance, heat exchanging efficiency, and thelike. Furthermore, a heat transfer plate to be disposed at the bottom isnot particularly limited to heat transfer plate A1. The same effect canbe obtained by laminating heat transfer plates with heat transfer plateB disposed at the bottom.

EXAMPLE 12

Next, Example 12 of the present invention is described with reference toFIGS. 35, 36, 37, 38 and 39.

The same members as those in Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 and11 are designated with the same reference numbers and regarded as havingthe same effects, and therefore detailed description thereof is omittedherein.

FIG. 35 is a schematic perspective view showing a heat exchanger used inthis Example; FIG. 36 is a schematic perspective view showing a state inwhich the heat transfer plates are laminated; and FIG. 37 is a schematicsectional view thereof.

As shown in FIGS. 35 and 36, side surface reinforcement convex portion38 is provided on the upper surface of outer peripheral rib A12 of heattransfer plate B2, and side surface reinforcement convex portion 38 isformed in a continuous shape with the width of, for example, 4 mm thatis equal to the width of outer peripheral rib A12 of heat transfer plateA1 and with the convex height of 4 mm with respect to the surface ofouter peripheral rib A12.

When heat transfer plates A1 and heat transfer plates B2 are laminatedalternately, as shown in FIG. 37, the upper surface of outer peripheralrib A12 formed on heat transfer plate A1 is brought into contact withthe rear surface of outer peripheral rib A12 formed on heat transferplate B2; the upper surface of outer peripheral rib A12 formed on heattransfer plate B2 is brought into contact with the rear surface of heattransfer surface 5 formed on heat transfer plate A1; and the uppersurface and the side surface of side surface reinforcement convexportion 38 formed on outer peripheral rib A12 of heat transfer plate B2are brought into contact with the rear surface and the side surface ofouter peripheral rib A12 formed on heat transfer plate A1.

According to the above-mentioned configuration, when adjacent surfacesof the outer side surfaces of outer peripheral ribs A12 of heatexchanger 21 are thermally welded to each other, a hollow convex portionof outer peripheral rib A12 of heat transfer plate A1 is brought intocontact with side surface reinforcement convex portion 38 of heattransfer plate B2. Thereby, after heated transfer plates are melted,when a temperature decreases and respective heat transfer plates arewelded, deformation of the side surface portion due to temperatureshrinkage is prevented, and deterioration of the sealing property due tothe deformation is further prevented. Thus, the sealing property of theside surface portion can be improved.

In this Example, side surface reinforcement convex portion 38 wasdescribed to have a continuous shape. As shown in FIGS. 38 and 39, evenwhen side surface reinforcement convex portion 38 is configured to havea discontinuous shape, the same effect can be obtained.

EXAMPLE 13

Next, Example 13 of the present invention is described with reference toFIGS. 40 and 41.

The same members as those in Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11and 12 are designated with the same reference numbers and regarded ashaving the same effects, and therefore detailed description thereof isomitted herein.

FIG. 40 is a schematic exploded perspective view showing a heatexchanger used in this Example; and FIG. 41 is a schematic perspectiveview showing a state in which heat transfer plates are laminated.

As shown in FIGS. 40 and 41, the width of outer peripheral rib A12 ofheat transfer plate A1 and heat transfer plate B2 is made to be, forexample, 4 mm and the convex height thereof is made to be 2 mm withrespect to the surface of heat transfer surface 5. Heat transfer plateA1 and heat transfer plate B2 have discontinuous side surfacereinforcement convex portion 38 on the upper surface of outer peripheralrib A12. The width of side surface reinforcement convex portion 38 ismade to be 4 mm that is equal to the above-mentioned width of outerperipheral rib A12 and the convex height thereof is 2 mm with respect tothe surface of outer peripheral rib A12. Furthermore, side surfacereinforcement convex portions 38 of heat transfer plate A1 and heattransfer plate B2 are configured so as to be dislocated with respect tothe laminating direction of heat transfer plates in which, when the heattransfer plates A1 and heat transfer plates B2 are laminatedalternately, the upper surface and the side surface of side surfacereinforcement convex portion 38 formed on heat transfer plate A1 arebrought into contact with the rear surface and the side surface of outerperipheral rib A12 formed on heat transfer plate B2, and the uppersurface and the side surface of side surface reinforcement convexportions 38 formed on heat transfer plate B2 are brought into contactwith the rear surface and the side surface of outer peripheral rib A12formed on heat transfer plate A1.

According to the above-mentioned configuration, when adjacent surfacesof the outer side surfaces of outer peripheral ribs A12 of heatexchanger 21 are thermally welded to each other, hollow convex portionsof outer peripheral ribs A12 of heat transfer plate A1 and heat transferplate B2 are brought into contact with respective side surfacereinforcement convex portions 38. Thereby, after heated transfer platesare melted, when a temperature decreases and respective heat transferplates are welded, deformation of the side surface portion due totemperature shrinkage is prevented, and deterioration of the sealingproperty due to the deformation is further prevented. Thus, the sealingproperty of the side surface portion can be improved.

EXAMPLE 14

Next, Example 14 of the present invention is described with reference toFIGS. 42 and 43.

The same members as those in Examples 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11,12 and 13 are designated with the same reference numbers and regarded ashaving the same effects, and therefore detailed description thereof isomitted herein.

FIG. 42 is a schematic exploded perspective view showing a heatexchanger used in this Example; and FIG. 43 is a schematic perspectiveview showing a state in which heat transfer plates are laminated.

As shown in FIGS. 42 and 43, the width of outer peripheral rib A12 ofheat transfer plate A1 and heat transfer plate B2 is made to be, forexample, 4 mm, the convex height of heat transfer plate A1 is made to be4 mm with respect to the surface of heat transfer surface 5, and theconvex height of heat transfer plate B2 is made to be 2 mm with respectto the surface of heat transfer surface 5. Heat transfer plate B2 hasdiscontinuous side surface reinforcement convex portion 38 on the uppersurface of outer peripheral rib 12. The width of side surfacereinforcement convex portion 38 is made to be 4 mm that is equal to thewidth of outer peripheral rib A12 and the convex height thereof is 4 mmwith respect to the surface of outer peripheral rib A12.

When heat transfer plates A1 and heat transfer plates B2 are laminatedalternately, the upper surface and the side surface of outer peripheralribs A12 formed on heat transfer plate A1 are brought into contact withthe rear surface and the side surface of outer peripheral rib A12 formedon heat transfer plate B2, the upper surface and the side surface ofside surface reinforcement convex portion 38 formed on outer peripheralrib A12 of heat transfer plate B2 are brought into contact with the rearsurface and the side surface of outer peripheral rib A12 formed on heattransfer plate A1.

According to the above-mentioned configuration, when adjacent surfacesof the outer side surfaces of outer peripheral ribs A12 of heatexchanger 21 are thermally welded to each other, a hollow convex portionof outer peripheral rib A12 of heat transfer plate A1 is brought intocontact with side surface reinforcement convex portion 38 of heattransfer plate B2. Thereby, after heated transfer plates are melted,when a temperature decreases and respective heat transfer plates arewelded, deformation of the side surface portion due to temperatureshrinkage is prevented, and deterioration of the sealing property due tothe deformation is further prevented. Thus, the sealing property of theside surface portion can be improved.

As is apparent from the above-mentioned Examples, according to thepresent invention, since the air flow passage rib, the outer peripheralrib A and the outer peripheral rib B are formed in a hollow shape byfolding one sheet into a convex shape, weight is reduced and an amountof materials to be cast can be reduced, so that material cost isreduced. The heat transfer plates are formed of a single material ofsheet material, so that high recycling property is achieved. Fluid flowsinto a hollow portion of the air flow passage ribs and heat exchange iscarried out also in the air flow passage ribs, thus improving the heatexchanging efficiency. Close contact between the groove A and groove B,close contact between the upper surface of the outer peripheral rib Aand the outer peripheral rib B and the heat transfer plate laminated inthe upper part thereof, and contact between the outer side surfaces makeit possible to seal between the air flow passage A and the air flowpassage B. Because of the close contact between the protrusions and theouter peripheral rib B and the groove B provided on a heat transferplates laminated in the upper part thereof, dislocation of heat transferplates does not easily occur, deterioration of the sealing property dueto the cutting accuracy and dislocation, and the like, of the heattransfer plates can be suppressed. Consequently, it is possible toobtain a heat exchanger in which the sealing property between the airflow passage A and the air flow passage B is high, laminating operationis easy and productive efficiency is high.

Furthermore, it is possible to obtain a heat exchanger in which heattransfer plates are easily molded into convex and concave shapes andwhich has an excellent productivity.

Furthermore, it is possible to obtain a heat exchanger having a highsealing property and a high operation efficiency since molded product ishard and less flexible.

Furthermore, it is possible to obtain a heat exchanger with a lowmaterial cost, excellent moldability or dimension stability and highproductive efficiency.

Furthermore, it is possible to obtain a heat exchanger with highproductive efficiency because an opening portion is formed on the outerside surface of outer peripheral rib B at the same time when a heattransfer plate is cut out of a molded sheet.

Furthermore, in at least two corner portions of heat transfer plate Aand heat transfer plate B, since overlapped portions of the adjacentheat transfer plates are thermally welded over the entire length in thelaminating direction and the laminated heat transfer plates are fixed toeach other, deterioration of a sealing property of air flow passage dueto dislocation of the heat transfer plates can be prevented.Consequently, it is possible to obtain a heat exchanger with a highsealing property.

Furthermore, on the surface on which the inlets and outlets of air flowpassages A and air flow passages B are formed, since overlapped portionsof the adjacent heat transfer plates are thermally welded over theentire surface, a sealing property of one air flow passage with respectto another air flow passage in the inlet and outlet portions of the airflow passages is improved. Consequently, it is possible to obtain a heatexchanger with a high sealing property.

Furthermore, since overlapped portions of the outer side surfaces of theadjacent heat transfer plates are thermally welded over the entiresurface and all the outer side surface portions of air flow passages aresealed, it is possible to obtain a heat exchanger with a high sealingproperty of air flow passages.

Furthermore, adjacent surfaces to be thermally welded are thermallywelded simultaneously, thereby it is possible to obtain a heat exchangerwith high productive efficiency.

Furthermore, it is possible to obtain a heat exchanger capable ofthermally welding individual surfaces to be thermally welded and havinga high sealing property.

Furthermore, since a thermal welding means moves while rotating in thedirection that is the same as the laminating direction, the outerperipheral side surfaces of heat transfer plates are pressed in the samedirection as the direction in which heat transfer plates are folded andthe upper surface of the surfaces to be thermally welded is pressed to alower surface reliably. Consequently, surfaces to be thermally weldedcan be welded reliably and a heat exchanger with a high sealing propertycan be obtained.

Furthermore, since a handle is provided in the direction perpendicularto the laminating direction of heat transfer plates or in the laminatingdirection of heat transfer plates, it is possible to obtain a heatexchanger capable of being attached and detached to/from equipment inthe laminating direction and in the direction perpendicular to thelaminating direction.

Furthermore, since a first end surface member and a support member areintegrated with each other, man-hour of coupling the first end surfacemember and the support member can be reduced. Consequently, it ispossible to obtain a heat exchanger with high productive efficiency.

Furthermore, since a second end surface member is affixed to heattransfer plates at both ends and at the same time, a band-like handlemember is fixed, it is possible to obtain a heat exchanger with highproductive efficiency. Since the second end surface member is formed ofan elastic body, it is possible to obtain a heat exchanger with a highsealing property at the end surface thereof when it is mounted onto theequipment.

Furthermore, since a band-like handle member is provided in thedirection perpendicular to the laminating direction of heat transferplates or in the laminating direction, it is possible to obtain a heatexchanger capable of being attached and detached to/from equipment inthe laminating direction and in the direction perpendicular to thelaminating direction. Since a second end surface member is affixed toheat transfer plates located at both end surface and at the same time, aband-like handle member is fixed, it is possible to obtain a heatexchanger with high productive efficiency. Since the second end surfacemember is formed of an elastic body, it is possible to obtain a heatexchanger with a high sealing property at the end surface of the heatexchanger when it is mounted onto the equipment.

Furthermore, when adjacent surfaces of the outer side surface of outerperipheral rib A of a heat exchanger are thermally welded, a hollowconvex portion of outer peripheral rib A of heat transfer plate A isbrought into contact with a side surface reinforcement convex portion ofheat transfer plate B. Thereby, after heated transfer plates are melted,when a temperature decreases and respective heat transfer plates arewelded, deformation of the side surface portion due to temperatureshrinkage is prevented, and deterioration of the sealing property due tothe deformation is further prevented. Thus, it is possible to obtain aheat exchanger with a high sealing property.

Furthermore, when adjacent surfaces of the outer side surface of outerperipheral rib A of a heat exchanger are thermally welded to each other,hollow convex portions of the outer peripheral ribs A of the heattransfer plate A and the heat transfer plate B are brought into contactwith the respective side surface reinforcement convex portions. Thereby,after heated transfer plates are melted, when a temperature decreasesand respective heat transfer plates are welded, deformation of the sidesurface portion due to temperature shrinkage is prevented, anddeterioration of the sealing property due to the deformation is furtherprevented. It is possible to obtain a heat exchanger with a high sealingproperty.

Furthermore, when the upper surface of the outer peripheral rib A of theheat transfer plate B is provided with the side surface reinforcementconvex portion and the heat transfer plates A and the heat transferplates B are laminated alternately, the upper surface of the outerperipheral rib A formed on the heat transfer plate A is brought intocontact with the rear surface of the outer peripheral rib A formed onthe heat transfer plate B, the upper surface of the outer peripheral ribA formed on the heat transfer plate B is brought into contact with therear surface of the heat transfer surface provided on the heat transferplate A, and the upper surface and the side surface of the side surfacereinforcement convex portion formed on the outer peripheral rib A of theheat transfer plate B is brought into contact with the rear surface andside surface of the outer peripheral rib A formed on the heat transferplate A.

According to the present invention, when adjacent surfaces of the outerside surface of the outer peripheral rib A of the heat exchanger arethermally welded, after heated transfer plates are melted, when atemperature decreases and respective heat transfer plates are welded,deformation of the side surface portion due to temperature shrinkage isprevented, and deterioration of sealing property due to deformation isfurther prevented. It is possible to obtain a heat exchanger with a highsealing property.

A side surface reinforcement convex portion having a discontinuous shapeis shown.

According to the present invention, when adjacent surfaces of the outerside surface of the outer peripheral rib A of the heat exchanger arethermally welded, after heated transfer plates are melted, when atemperature decreases and respective heat transfer plates are welded,deformation of the side surface portion due to temperature shrinkage isprevented, and deterioration of a sealing property due to deformation isfurther prevented. Thus, it is possible to obtain a heat exchanger witha high sealing property.

Furthermore, when a side surface reinforcement convex portions isprovided on the upper surface of the outer peripheral rib A of the heattransfer plate A and the heat transfer plate B and the heat transferplates A and the heat transfer plates B are laminated alternately, theupper surface and the side surface of the side surface reinforcementconvex portion formed on the heat transfer plate A are brought intocontact with the rear surface and the side surface of the outerperipheral rib A formed on the heat transfer plate B, and the uppersurface and the side surface of the side surface reinforcement convexportion formed on the heat transfer plate B are brought into contactwith the rear surface and the side surface of the outer peripheral rib Aformed on the heat transfer plate A.

According to the present invention, when adjacent surfaces of the outerside surface of the outer peripheral rib A of the heat exchanger arethermally welded, after heated transfer plates are melted, when atemperature decreases and respective heat transfer plates are welded,deformation of the side surface portion due to temperature shrinkage isprevented, and deterioration of a sealing property due to deformation isfurther prevented. Thus, it is possible to obtain a heat exchanger witha high sealing property.

Furthermore, when the heat transfer plates A and the heat transferplates B are laminated alternately, the upper surface and the sidesurface of the outer peripheral rib A formed on the heat transfer plateA are brought into contact with the rear surface and side surface of theouter peripheral rib A formed on the heat transfer plate B, and theupper surface and the side surface of the side surface reinforcementconvex portion formed on the outer peripheral rib A of the heat transferplate B are brought into contact with the rear surface and side surfaceof the outer peripheral rib A formed on the heat transfer plate A.

According to the present invention, when adjacent surfaces of the outerside surfaces of the outer peripheral ribs A of the heat exchanger arethermally welded, after heated transfer plates are melted, when atemperature decreases and respective heat transfer plates are welded,deformation of the side surface portion due to temperature shrinkage isprevented, and deterioration of a sealing property due to deformation isfurther prevented. Thus, it is possible to obtain a heat exchanger witha high sealing property.

INDUSTRIAL APPLICABILITY

The present invention provides a heat exchanger for use in heatexchanging ventilation equipment or other air conditioning equipment, inwhich multiple heat transfer plates are laminated alternately and airflow passages A and air flow passages B are formed alternately. The heatexchanger according to the present invention has light weight, anexcellent recycling property and an excellent sealing property of airflow passages without using an adhesive agent.

1. A heat exchanger comprising: a heat transfer plate A and a heattransfer plate B; a plurality of air flow passage ribs formed in asubstantially S-shaped hollow convex and disposed substantially parallelto each other and substantially at equal intervals, the plurality of airflow passage ribs forming a plurality of substantially S-shaped air flowpassages and heat transfer surfaces; an air flow passage end surfaceprovided at an inlet and an outlet of the air flow passage of the heattransfer plate A, the air flow passage end surface being providedobliquely or perpendicular to a direction of the inlet and outlet of theair flow passage and provided by folding the heat transfer surface in adirection opposite to a convex direction of the air flow passage rib; agroove A provided parallel to the air flow passage end surface on theheat transfer plate A; a plurality of protrusions each having a hollowshape being convex in the same direction as the convex direction of theair flow passage rib, which are provided between the groove A and theair flow passage end surface on extended lines of the plurality of airflow passage ribs on the heat transfer surface in the vicinity of theair flow passage end surface, each of the plurality of protrusionshaving a pair of side surfaces substantially parallel to the air flowpassage end surface and being higher than a height in the convexdirection of the plurality of air flow passage ribs; outer peripheraledge portions being other than portions of the inlets and outlets of theair flow passages on the heat transfer plate, the outer peripheral edgeportions including one pair of outer peripheral edge portions A facingeach other and being adjacent to the inlets and outlets of the air flowpassages and which are provided substantially parallel to substantiallycentral portions of the plurality of substantially S-shaped air flowpassage ribs, and another pair of outer peripheral edge portions Bfacing each other and being adjacent to the inlets and outlets of theair flow passages and which are provided substantially parallel to theair flow passage rib in the portion of the inlets and outlets of theplurality of substantially S-shaped air flow passages; the outerperipheral edge portion A having an outer peripheral rib A obtained byforming the heat transfer surface into a hollow shape that is convex inthe same direction as the convex direction of the air flow passage rib,in which a convex height of the outer peripheral rib A is higher than aheight in a convex direction of the air flow passage rib A and an outerside surface of the outer peripheral rib A is folded in a directionopposite to the convex direction of the air flow passage rib so as tohave a folding dimension that is larger than a dimension of the heightin the convex direction of the outer peripheral rib A with respect tothe heat transfer surface; the outer peripheral edge portion B having anouter peripheral rib B obtained by forming the heat transfer surfaceinto a hollow shape that is convex in the same direction as the convexdirection of the air flow passage rib, in which a convex height of theouter peripheral rib B is the same height in a convex direction of theair flow passage rib B and a central portion of an outer side surface ofthe outer peripheral rib B is folded to the same plane as the heattransfer surface so as to have an opening portion at the outer sidesurface of the outer peripheral rib B; an air flow passage end surfacecover provided at both ends of the outer side surface of the outerperipheral rib B, which is folded to the same position as the foldingposition of the air flow passage end surface; and a groove B provided onan upper surface of the outer peripheral rib B, the groove B being cavedto the same plane as the heat transfer surface, on a position in which adistance between a side surface of the outer peripheral rib B and acenter line of the groove B is equal to a distance between a center lineof the groove A and the air flow passage end surface, in a shape inwhich an outer surface in a longitudinal direction of the groove A isbrought into close contact with an inner surface in a longitudinaldirection of the groove B, wherein the heat transfer plate B ismirror-image relation to the heat transfer plate A; in a shape of theheat transfer plate B, a height in a convex direction of the outerperipheral rib A of the heat transfer plate B is allowed to be the sameas a height in a convex direction of the air flow passage rib;furthermore, a width of the outer peripheral rib A of the heat transferplate B is larger than a width of the outer peripheral rib A provided inthe heat transfer plate A; each of the heat transfer plate A and theheat transfer plate B is integrated by using one sheet as a material,respectively; the heat transfer plates A and the heat transfer plates Bare laminated alternately in a way in which the outer peripheral rib Aof the heat transfer plate A and the outer peripheral rib A of the heattransfer plate B are overlapped with each other; and the heat transferplates A and the heat transfer plates B are laminated to each other,resulting in forming the air flow passage A and the air flow passage Balternately; and wherein, when the heat transfer plates A and the heattransfer plates B are laminated alternately, upper surfaces of the airflow passage ribs, the protrusions, the outer peripheral ribs A and theouter peripheral ribs B are brought into contact with a heat transferplate to be laminated on an upper part thereof; the groove B is broughtinto contact with an upper surface of the outer peripheral rib Bprovided on a heat transfer plate located in a lower part of the grooveB; a pair of side surfaces of the protrusions being parallel to the airflow passage end surface are brought into contact with at least one ofan inner side surface of the outer peripheral rib B and a side surfaceof the groove B provided in the heat transfer plate to be laminated onan upper part of the protrusions; the air flow passage end surface isbrought into contact with an outer side surface of the outer peripheralrib B provided on a heat transfer plate located in a lower part of theair flow passage end surface; side surfaces of the outer peripheral ribsA provided respectively on the heat transfer plate A and the heattransfer plate B are brought into contact with each other; and the airflow passage end surface cover is brought into contact with an endsurface of the outer peripheral rib A and the outer peripheral rib Bprovided on a heat transfer plate located in a lower part of the airflow passage end surface cover.
 2. The heat exchanger according to claim1, wherein the sheet is a thermoplastic resin sheet.
 3. The heatexchanger according to claim 1, wherein the sheet is a styrene resinsheet.
 4. The heat exchanger according to claim 1, wherein the sheet isa polystyrene resin sheet.
 5. The heat exchanger according to claim 1,wherein when the heat transfer plates A and the heat transfer plates Bare integrated with each other, by carrying out a molding process by theuse of a molding die having a rectangular shaped portion that continuesto the outer side surface of the outer peripheral rib B and has a crosssectional shape equal to an opening portion formed on the outer sidesurface of the outer peripheral rib B, and then cutting a portion formedby the rectangular shaped portion and a sheet portion other than theheat transfer plate A and the heat transfer plate B along the outer sidesurfaces of the heat transfer plate A and the heat transfer plate B, theheat transfer plate A and the heat transfer plate B are manufactured. 6.The heat exchanger according to claim 1, wherein in at least two cornerportions of the heat transfer plate A and the heat transfer plate B,overlapped portions of the air flow passage end surface cover, the outerperipheral rib A, the outer peripheral rib B or the air flow passage endsurface, which are formed on an outer side surface of adjacent heattransfer plates, are thermally welded over an entire length in thelaminated direction.
 7. The heat exchanger according to claim 1, whereinin a surface on which the inlets and outlets of the air flow passages Aand the air flow passages B are formed, overlapped portions of the airflow passage end surface cover, the outer peripheral rib A, the outerperipheral rib B and the air flow passage end surface, which are formedon an outer side surface of adjacent heat transfer plates, are thermallywelded over an entire surface.
 8. The heat exchanger according to claim1, wherein overlapped portions on an outer side surface of adjacent heattransfer plates are thermally welded over an entire surface.
 9. The heatexchanger according to claim 1, wherein when adjacent portions on anouter side surface of the heat exchanger is thermally welded, theadjacent portions on an outer side surface of the heat exchanger isthermally welded simultaneously by a thermal welding means having athermally welding surface having a shape corresponding to a shape of theadjacent portions on an outer side surface of the heat exchanger. 10.The heat exchanger according to claim 1, wherein when adjacent portionson an outer side surface of the heat exchanger are thermally welded, byvertically pressing a thermal welding means having substantially thesame shape as respective surfaces to be thermally welded to a surface tobe thermally welded, the outer side surface of the heat exchanger isthermally welded.
 11. The heat exchanger according to claim 1, whereinthe outer side surface of the heat exchanger is thermally welded by theuse of a thermal welding means having a cylindrical-shaped thermallywelding surface, by pressing the thermally welding surface of thethermal welding means to the heat exchanger and moving while rotating itfrom an upper part to a lower part along a laminating direction of theheat transfer plates.
 12. The heat exchanger according to any one ofclaims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 and 11, comprising: the first endsurface members, which are facing each other, at both end surfaces inthe laminating direction in which the heat transfer plates A and theheat transfer plates B are laminated alternately; a side surface platecovering an outer side surface of the laminated heat transfer plates Aand the heat transfer plates B and which is provided at an outerperipheral edge portion of the first end surface member; a supportmember provided on an outer side surface of the outer peripheral rib Aof the laminated heat transfer plates with both ends thereof coupled tothe first end surface members; elastic bodies included between the firstend surface members and the heat transfer plates located at both ends,respectively, the elastic body having a shape of pressing at least outerperipheral edge portions of the heat transfer plates located at both endsurfaces; and a handle provided on at least one of the first end surfacemember and the support member.
 13. The heat exchanger according to anyone of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 and 11, wherein the firstend surface members and the support members are integrated with eachother with one of the support members separated; the first end surfacemembers are disposed so that the first end surface members facing eachother via the elastic bodies respectively at both end surfaces in thedirection in which the heat transfer plates A and the heat transferplates B are laminated; and the support members are disposed at theouter side surface of the outer peripheral rib A of the laminated heattransfer plates in which the separated portions of the separated supportmember are coupled to each other.
 14. The heat exchanger according toany one of claims 6, 7, 8, 9, 10 and 11, comprising second end surfacemembers affixed to heat transfer plates located at both end surfaces ofthe alternately laminated heat transfer plates A and heat transferplates B, the second end surface member being formed of an elastic bodymolded in a shape that is the same as a shape of the outer peripheraledge portion of at least the heat transfer plate A or the heat transferplate B; and a band-like handle member provided along at least one sidesurface of the outer side surface of the outer peripheral rib A, theband-like handle member being fixed to the heat transfer plates locatedat both end surfaces by the second end surface members.
 15. The heatexchanger according to any one of claims 6, 7, 8, 9, 10 and 11,comprising second end surface members affixed to heat transfer plateslocated at both end surfaces of the alternately laminated heat transferplates A and heat transfer plates B, the second end surface member beingformed of an elastic body molded in a shape that is the same as a shapeof the outer peripheral edge portion of at least the heat transfer plateA or the heat transfer plate B; and a band-like handle member providedalong the outer side surface of the outer peripheral rib A, theband-like handle member being fixed to the heat transfer plate locatedat the end surface by the second end surface member at one end surfacein the laminating direction of the laminated heat transfer plates, anddisposed at the outside of the second end surface member at another endin the laminating direction of the laminated heat transfer plates. 16.The heat exchanger according to claim 1, wherein a side surfacereinforcement convex portion is provided on an upper surface of theouter peripheral rib A of the heat transfer plate B, and when the heattransfer plates A and the heat transfer plates B are laminatedalternately, an upper surface of the outer peripheral rib A formed onthe heat transfer plate A is brought into contact with a rear surface ofthe outer peripheral rib A formed on the heat transfer plate B, an uppersurface of the outer peripheral rib A formed on the heat transfer plateB is brought into contact with a rear surface of the heat transfersurface provided on the heat transfer plate A, and an upper surface anda side surface of the side surface reinforcement convex upper surfaceformed on the outer peripheral rib A of the heat transfer plate B arebrought into contact with a rear surface and a side surface of the outerperipheral rib A formed on the heat transfer plate A.
 17. The heatexchanger according to claim 16, wherein the side surface reinforcementconvex portion is formed in a discontinuous shape.
 18. The heatexchanger according to claim 17, wherein a side surface reinforcementconvex portion is provided on an upper surface of the outer peripheralrib A of the heat transfer plate A and the heat transfer plate B, andwhen the heat transfer plates A and the heat transfer plates B arelaminated alternately, an upper surface and a side surface of the sidesurface reinforcement convex portion formed on the heat transfer plate Aare brought into contact with a rear surface and a side surface of theouter peripheral rib A formed on the heat transfer plate B, and an uppersurface and a side surface of the side surface reinforcement convexportion formed on the heat transfer plate B are brought into contactwith a rear surface and a side surface of the outer peripheral rib A.19. The heat exchanger according to claim 17, wherein when the heattransfer plates A and the heat transfer plates B are laminatedalternately, an upper surface and a side surface of the outer peripheralrib A formed on the heat transfer plate A are brought into contact witha rear surface and a side surface of the outer peripheral rib A formedon the heat transfer plate B, and an upper surface and a side surface ofthe side surface reinforcement convex portion formed on the outerperipheral rib A of the heat transfer plate B are brought into contactwith a rear surface and a side surface of the outer peripheral rib Aformed on the heat transfer plate A.
 20. A heat transfer plate,comprising a plurality of ribs defining a plurality of air flowpassages; outer ribs along opposite edges of said heat transfer plate,each of said outer ribs including a respective groove; a plurality ofprotrusions along a further edge of said heat transfer plate, saidprotrusions separated from each other by said air flow passages; agroove extending along said protrusions on a side of said protrusionsaway from said further edge.
 21. A heat exchanger, comprising aplurality of heat transfer plates, each comprising a plurality of ribsdefining a plurality of air flow passages; outer ribs along oppositeedges of said heat transfer plate, each of said outer ribs including arespective groove; a plurality of protrusions along a further edge ofsaid heat transfer plate, said protrusions separated from each other bysaid air flow passages; a groove extending along said protrusions on aside of said protrusions away from said further edge, wherein one ofsaid opposite edges of one of said heat transfer plates is placed alongsaid further edge of another of said heat transfer plates.